HAZARD STUDY 1: REPORTING

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HAZARD STUDY 1: REPORTING
CONTENTS:
1.0 Actions Agreed
1.1 Project Definition
1.2 Process Description
1.3 Control Philosophy
1.4 Incident Review
1.5 Inherent SHE
1.6 Materials Hazards
1.7 Safety
1.8 Health
1.9 Environment
1.10 Transport and Siting
1.11 External Authorities
1.12 Design Guidelines and Codes
1.13 Organization
1.14 Emergency Facilities
1.15 Further Studies
1.16 Conclusion


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HAZARD STUDY 1: REPORTING

  1. 1. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown 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 / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals 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-PGP-009 HAZARD STUDY 1: REPORTING 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.
  2. 2. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown 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 / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com HAZARD STUDY REPORT Project Title Doc ref.: Project file: Issue : Approved for issue by: Date: Signature: HAZARD STUDY TEAM: Hazard Study Leader: Project Manager: Functional Engineers: Operations or Site Representative: SHE Manager:
  3. 3. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown 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 / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com CONTENTS: 1.0 Actions Agreed 1.1 Project Definition 1.2 Process Description 1.3 Control Philosophy 1.4 Incident Review 1.5 Inherent SHE 1.6 Materials Hazards 1.7 Safety 1.8 Health 1.9 Environment 1.10 Transport and Siting 1.11 External Authorities 1.12 Design Guidelines and Codes 1.13 Organization 1.14 Emergency Facilities 1.15 Further Studies 1.16 Conclusion Circulation: Hazard Study Team
  4. 4. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown 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 / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 1.0 ACTIONS AGREED 1.1 PROJECT DEFINITION 1.2 PROCESS DESCRIPTION 1.3 CONTROL PHILOSOPHY 1.4 INCIDENT REVIEW 1.5 INHERENT SHE Eight GBHE Process SSHE Questions 1) What alternative routes or processes can be used to allow substances or solvents of lower impact on man and the environment to be considered? (2) What alternative routes or processes can be used to minimize the inventories of hazardous substances? (3) What alternative routes or processes can be used to make process conditions as benign as possible? (4) What is the ultimate fate of all substances used in the process that are not part of the product? (5) How will processing stages permit internal recycles with minimum or nil purges? (6) Can the effluents be further processed to allow a recycle or a better means of disposal?
  5. 5. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown 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 / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com (7) What are the consequences on man and the environment of the release of any of the materials during processing, transport and storage (including both normal and abnormal conditions)? (8) What is the impact on capital and operating costs of lower SHE impact options and higher safety, health or environmental standards? 1.6 MATERIALS HAZARDS 1.6.1 Materials List See the Materials List - (Part 1 of 3). 1.6.2 Hazard Data Sheets All Material Safety Data Sheets are available. 1.6.3 Chemical Hazards See the Chemical Hazards pro-forma - (Part 2 of 3) See the Means of Handling pro-forma - (Part 3 of 3) See the Chemical Interactions pro-forma
  6. 6. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown 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 / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com Looking for issues regarding process robustness (i.e. an indication of how sensitive the process is to deviations from the process recipe). Is the reaction sensitive to: (a) Agitation failure? (b) Late or fast dump addition of a reagent? (c) Cooling failure? (d) Water ingress? (e) Level of heating? (f) Over/undercharge of reagent? (g) The wrong concentration/grade of material being used? (h) The wrong ratio of reactants is used? (j) Addition of a material at the wrong stage? (k) The order of addition, rate of addition, method of addition of any material? (l) The order of introduction of functional groups? (m) Contamination? (n) Stabilizers? (p) Change of raw materials? (q) pH? (r) Scrubber failure? (s) Failure of vacuum, nitrogen, air or other gas? (t) Condenser failure? (u) Blockages
  7. 7. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown 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 / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 1.6.4 Loss of Containment Solids Gases Liquids 1.7 SAFETY Toxic gas emission criteria: Employee risk criteria: Off-site individual risk criteria: Off-site group risk criteria: Major incident frequency criteria: See also Section 1.9.3. 1.8 HEALTH Draft Occupational Health Statement available? Health hazards from: - (a) Chemical & biological properties: (b) Noise & vibration: (c) Ergonomics: (d) Radiation: Construction / Commissioning / Operation / Maintenance / Demolition all considered? Criteria & standards established?
  8. 8. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown 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 / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 1.9 ENVIRONMENT 1.9.1 Environmental Statement 1.9.2 Loss of Containment See Section 1.6.4. 1.9.3 GBHE Objectives The Project will be carried out in accordance with SSHE Objectives. 1.9.4 Environmental Impact No additional comments. 1.9.5 Environmental Criteria No additional comments. 1.10 TRANSPORT AND SITING 1.10.1 Transport Stages 1.10.2 Loss of Containment 1.10.3 Existing Plant 1.10.4 Other Considerations
  9. 9. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown 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 / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com 1.11 EXTERNAL AUTHORITIES Change of plant or site status? Plant or site inventories updated? Chemicals controlled by international protocol? Which authorities need to be contacted and who will be responsible? 1.12 DESIGN GUIDELINES AND CODES Standard GBHE guidelines will be followed. 1.13 ORGANIZATION (a) Suitability and availability of staff : (b) New systems of work or procedures: (c) Key operational and manning concepts: (d) Construction manning: 1.14 EMERGENCY FACILITIES 1.15 FURTHER STUDIES (a) Construction/demolition hazards (HAZCON) (b) Area classification (c) Fire prevention and protection (d) Paving and drainage (e) Cable routing (f) Relief and blowdown
  10. 10. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown 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 / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com (g) Lifting equipment (h) Noise (j) Trip and alarms (k) Layout (l) Computer systems (m) Control and operability (n) Non-process hazards (p) Equipment and pipework registration (q) Critical machines (r) Business risk (s) Fire water run-off (t) Building risk assessment (Process SHE Guide) (u) Means of isolation (v) Materials review (w) Ergonomics 1.16 CONCLUSION Responsibility and date for progressing actions?
  11. 11. Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown 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 / Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries Web Site: www.GBHEnterprises.com

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