HAZCON / HAZDEM
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HAZCON / HAZDEM

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HAZCON / HAZDEM
CONTENTS
1.0 PURPOSE
1.0.1 Team
1.0.2 Timing
1.0.3 Preparation
1.0.4 Documentation
HAZCON / HAZDEM: APPLICATION
1.1 SPECIFICATION OF THE WORK
a) HAZCON
b) HAZDEM
1.2 METHOD STATEMENT
1.3 HAZCON STUDY
1.4 HAZDEM STUDY
1.5 MONITORING OF ACTIVITIES
1.6 REVIEW OF HAZARD STUDY

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HAZCON / HAZDEM HAZCON / HAZDEM Document Transcript

  • 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-004 HAZCON / HAZDEM 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.
  • 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 Process Safety Guide: HAZCON/ HAZDEM CONTENTS 1.0 PURPOSE 1.0.1 Team 1.0.2 Timing 1.0.3 Preparation 1.0.4 Documentation HAZCON / HAZDEM: APPLICATION 1.1 SPECIFICATION OF THE WORK a) HAZCON b) HAZDEM 1.2 METHOD STATEMENT 1.3 HAZCON STUDY 1.4 HAZDEM STUDY 1.5 MONITORING OF ACTIVITIES 1.6 REVIEW OF HAZARD STUDY
  • 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 PURPOSE It covers Construction Hazard Assessments (HAZCON) and Demolition Hazard Assessments (HAZDEM). HAZCON and HAZDEM studies are intended to identify the hazards and assess the risks likely from significant installation/construction and demolition work, and ensure that practical safeguards are in place that minimizes the likelihood of accidents. They may be applied to both new plant work, and maintenance or modification work and would normally be considered following Hazard Study 3 stage. The HAZCON and HAZDEM studies are intended to be flexible so that it can be used efficiently for both small internal work and large construction projects. It is critical therefore that the Project Manager (or his nominated deputy), are competent to make a judgment on the extent of the information, documentation, and additional consultation required to minimize construction/installation risks. In countries where hazard construction legislation exists, the HAZCON and HAZDEM studies should form part of the legislative safety system requirements, without the need for duplication of any parts of the study process. Where external contractors are being used in the installation and construction work this may result in additional costs to implement safeguards identified in the HAZCON. The Project Manager (or his nominated deputy) is responsible for ensuring that HAZCON and HAZDEM are carried out and implemented. 1.0.1 Team Dependent on the size of the construction/installation work the Project Manager (or his nominated deputy) will judge the size and make-up of the HAZCON or HAZDEM study team. For large contracts using external contractors the Contract Manager will require members of the Contractors management to be involved in the study. For small on-site work the Project Manager (or his nominated deputy) may carry out the study alone, or with the construction or demolition crew.
  • 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 1.0.2 Timing The study should be completed prior to the commencement of on-site operations. 1.0.3 Preparation To carry out a HAZCON or HAZDEM study the following information is normally required: • A clear specification of the work and conditions to be met; • A method statement of how the work will be completed. A risk assessment can then be made, and where necessary safeguard actions proposed and implemented. 1.0.4 Documentation For work undertaken by external contractors the necessary elements making up the documentation for HAZCON or HAZDEN should be provided for in the procurement/tender package.
  • 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 HAZCON / HAZDEM: APPLICATION The following sections 1.1 to 1.6 describe how to conduct a HAZCON / HAZDEM study 1.1 SPECIFICATION OF THE WORK (a) HAZCON The Project Manager (or his nominated deputy) should prepare a specification of the work required. Dependent on the scale of work this should include: (1) A clear description of the extent of supply, installation, and construction work required. (2) Details of the contacts and individuals that will be responsible for management and supervision of the work.
  • 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 (3) Detailed layout and engineering design drawings of the requirements. (4) Installation instructions of any ’free-issue’ plant. (5) A description of the site, location, activities present, and site procedures (e.g. ’Permit To Work’) that have to be followed. (6) Details of other construction and demolition work by other groups in the vicinity. (7) Known hazards that should be taken into consideration. (8) Timetable, including start and completion dates, normal hours of work and no-go limitations. (9) Conditions and regulations that the work shall be completed under, (including training, safety inductions, site entry/exit restraints, and commercial aspects). (10) Testing, commissioning and handover requirements. (11) Other information as deemed relevant by the Project Manager (or his nominated deputy). (b) HAZDEM The Project Manager (or his nominated deputy) should prepare a specification of the work required. Dependent on the scale of work this should include: (1) A clear description of the extent of demolition work required. (2) Details of the contacts and individuals that will be responsible for management and supervision of the work. (3) Detailed layout and engineering design drawings of the requirements. (4) A description of the site, location, activities present, and site procedures (e.g. ’Permit To Work’) that have to be followed.
  • 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 (5) Details of other demolition and construction work by other groups in the vicinity. (6) Known hazards that should be taken into consideration. (7) Timetable, including start and completion dates, normal hours of work and no-go limitations. (8) Conditions and regulations that the work shall be completed under, (including training, safety inductions, site entry/exit restraints, and commercial aspects). (9) Other information as deemed relevant by the Project Manager (or his nominated deputy). 1.2 METHOD STATEMENT Based on the interpretation of the specification of the work package, the Construction Manager (which for internal work may be the Project Manager (or his nominated deputy), or for external sourced work, the Contractor), should prepare a ’method statement’. The method statement informs the Project Manager how the work will be completed in accordance with all the requirements, and the level of consideration given to safety. Method statements should be unique to each individual project, i.e. generic ones should be avoided) and should include as appropriate: (a) A sequence of construction/installation or demolition events. (b) Timetable for completion of the work. (c) Expected manning levels, disciplines, and sub-contractors for each sequence. (d) Specialist machinery and equipment to be used. (e) PPE and safety equipment to be provided. (f) Special training required for specific tasks. (g) Hazardous techniques to be used. (h) Entry and exit routes.
  • 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 (j) Site accommodation details, storage area locations, delivery and offloading and fabrication bays. (k) Requirements for segregated areas. (l) Requirements for manufacturing downtime, or operation disruption. (m) Security arrangements. (n) Impact of weather. (p) Arrangements for maintaining clean and tidy work areas. (q) Safety management systems to be used, e.g. Permit to Work, scaffold inspection, site induction, training records. (r) Identification of the individuals responsible for ensuring compliance with the method statement and construction audit. 1.3 HAZCON STUDY The HAZCON should include: • A description of the scope and specification of the work; • The method statement; • The HAZCON Checklist (checklist k1); • The HAZCON Action List (worksheet x1); • Recommendations for training and briefing construction personnel; • Special conditions to be included in monitoring. The method statement should be analyzed to identify any hazards and these assessed to determine what safeguards are required. The sequence of events or operations for the work should be considered one by one, and those considered requiring actions are recorded and noted on a HAZCON Action List (worksheet x1). Note: On large projects the Project Manager (or his nominated deputy) should judge the scale of the HAZCON study and where worksheet x1 is unlikely to be suitable, and then the HAZCON Review worksheet (worksheet w1) is available as an alternative.
  • 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 1.4 HAZDEM STUDY The HAZDEM should include: • A description of the scope and specification of the work; • The method statement; • The HAZDEM Checklist (checklist k2); • The HAZDEM Action List (worksheet x2); • Recommendations for training and briefing construction personnel; • Special conditions to be included in monitoring. The method statement should be analyzed to identify any hazards and these assessed to determine what safeguards are required. The sequence of events or operations for the work should be considered one by one, and those considered requiring actions are recorded and noted on a HAZDEM Action List (worksheet x2). Note: On large projects the Project Manager (or his nominated deputy) should judge the scale of the HAZDEM study and where worksheet x2 is unlikely to be suitable, and then the HAZDEM Review worksheet (worksheet w2) is available as an alternative.
  • 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 1.5 MONITORING OF ACTIVITIES Following a study, the Project Manager (or his nominated deputy) should ensure that all hazards, special procedures, and training requirements are delivered as appropriate, to the demolition team. This should be in addition to usual requirements, e.g. induction, plant entry/exit procedures, Permit to Work, PPE. It is essential to monitor activities to ensure that the work is implemented compliant with the agreed method statement, safeguards, procedures, and special precautions. Monitoring should be carried out on a regular basis, appropriate to the scale and type of the work. Checklists should be drawn up that cover all SHE requirements, and a system in place for prompt attention to non-conformances. These should be recorded on the Hazard Study Action Review (worksheet h). Complete monitoring exercises should be filed by the Project Manager (or his nominated deputy), and retained in the SSHE dossier. 1.6 REVIEW OF HAZARD STUDY At the completion of the study the following key activities should have been completed: • Actions should have been assessed, reviewed and closed out. • All conclusions should be documented and filed by the Project Manager (or his nominated deputy), and retained in the SSHE dossier. The Project Manager is responsible for progressing identified actions.
  • 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