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1. INDUSTRIAL SAFETY & HAZARD MANAGEMENT DIPANKAR DAS ASSISTANT PROFESSOR JNTUH COLLEGE OF ENGINEERING, HYDERABAD

2. UNIT- IV Hazard analysis: process safety management, process hazards analysis, hazards analysis methods, check list, preliminary hazard analysis, what-if / check list, hazard and operability analysis, FMEA, Fault tree analysis, cause and consequence analysis REFERENCE : Book : Chemical Process Industry Safety – K.S.N Raju Chapter -5 , Page Nos 286 - 328

3. SIMPLE CHECK LIST QUESTIONAIRE

4. SIMPLE CHECK LIST QUESTIONAIRE

5. SIMPLE CHECK LIST QUESTIONAIRE (WORKPLACE SAFETY ) Template Preview Description of worksite activities List hazardous chemicals and substances that are handled, stored and disposed of PEOPLE Are all workers trained in safe procedures when working with hazardous chemicals? Yes No N/A Are all employees wearing appropriate PPE? Yes No N/A Are all employees aware of emergency procedures in case of an accident involving hazardous chemicals? Yes No N/A Are all employees aware of the Permissible Exposure Limits (PEL)? Yes No N/A

6. SIMPLE CHECK LIST QUESTIONAIRE (HAZARDOUS CHEMICALS) D o employees follow safe handling instruction of hazardous chemicals? Yes No N/A Do employees wash their hands before and after handling chemicals? Yes No N/A WORKING AREA Is there an exhaust fan or open window for adequate ventilation, when using hazardous chemicals? Yes No N/A Are eye-wash fountains and safety showers provided in areas where corrosive chemicals are handled? Yes No N/A

7. SIMPLE CHECK LIST QUESTIONAIRE (STORAGE SYSTEM) REFERENCE: Chemical containers are clearly labeled [This is an example of how you can use Auditor to include best practice reference images in your templates to assist with inspections] Are all chemical container lids tightly sealed? Yes No N/A Are all chemical containers free from dents and in good working condition? Yes No N/A Is all packaging free from leakage? Yes No N/A

8. SIMPLE CHECK LIST QUESTIONAIRE ( WASTE DISPOSAL) DISPOSAL Are waste chemicals labeled as waste and stored in a suitable location until final disposal? Yes No N/A Are facilities available for different chemical waste streams (solid waste, liquid waste)? Yes No N/A Are bins clearly marked with their waste stream? Yes No N/A Are containers tightly closed? Yes No N/A Are standard operating procedures established and are they being followed when cleaning up chemical spills? Yes No N/A

9. SIMPLE CHECK LIST QUESTIONAIRE (WASTE DISPOSAL) Is there a dedicated sink for acceptable liquid waste? Yes No N/A Is the sink clearly marked up? Yes No N/A Are “Hazardous Waste” signs in place and clearly visible? Yes No N/A Are waste chemicals disposed of promptly? Yes No N/A Are all waste containers stored in waste storage area? Yes No N/A

10. HAZOP CASE STUDY

11. HAZOP STUDY SUGGESTS SOME MODIFICATION

12. What is Fault Tree Analysis Fault tree analysis (FTA) is a graphical tool to explore the causes of system level failures. It uses boolean logic to combine a series of lower level events and it is basically a top-down approach to identify the component level failures (basic event) that cause the system level failure (top event) to occur. Fault tree analysis consists of two elements “events” and “logic gates” which connect the events to identify the cause of the top undesired event. Fault tree analysis is an easier method than the  Failure Mode and Effects Analysis (FMEA)  as it focuses on all possible system failures of an undesired top event. Whereas  FMEA  conducts analysis to find all possible system failure modes irrespective of their severity . History of Fault Tree Analysis Fault tree analysis is a top down approach that was originally developed in Bell laboratories by H Waston and A Mearns for the air force in the year 1962. This concept later adopted by Boeing and today it is widely used in aerospace, automobile, chemical, nuclear and software industries especially reliability and safety related events. When Would You Use FTA Fault tree analysis can be used to perform for all types of system level risk assessment process. The purpose of FTA is to effectively identify cause(s) of system failure and mitigate the risks before it occurs. This is an invaluable tool for complex systems that visually displays the logical way of identifying the problem. Moreover system efficiency can be attained by this analysis. It can be implemented alone or complement to  Failure Mode and Effects Analysis (FMEA).

13. FTA Symbols Fault tree uses logical gates to perform the analysis. There are numerous FTA symbols exists, but these are broadly divided in to two categories, Event symbols and Gate symbols. Event Symbols in FTA

14. How do you do Fault Tree Analysis Define the primary failure to be analyzed in other words identify the undesirable top event Identify first level contributors which are just below the top level using the available technical information Link these contributors to top level event by using logical gates (AND, OR gates), and also see the relationship, so that it will help to identify the appropriate logical gate Identify the second level contributors and link to top by using logical gates. Identify minimal cut set Repeat the same steps till the basic causes Finally complete and evaluate the FTA Calculate probability of lowest level elements occurrence and also measure the probabilities from bottom up

15. FTA FOR FIRE ACCIDENT

16. Advantages of Fault tree analysis Fault tree visually depict the analysis that will help team to work on cause of event in logical way that leads to failure Highlights the critical components related to system failure Provides an efficient method to analyze the system Unlike other analysis methods, human errors are also include in the analysis It helps to prioritize the action items to solve the problem Provides qualitative and quantitative analysis Disadvantages of Fault tree analysis Too many gates and events to be consider for large system analysis The basic disadvantage is that it examine only one top event Common cause failures are not always obvious Difficult to capture time related and other delay factors Needs experienced individuals to understand the logical gates

17. Failure mode and effect analysis Failure Mode and Effects Analysis (FMEA) Begun in the 1940s by the U.S. military, failure modes and effects analysis (FMEA) is  a step-by-step approach for identifying all possible failures in a design, a manufacturing or assembly process, or a product or service . It is a common process analysis tool . Ground rule The ground rules of each FMEA include a set of project selected procedures; the assumptions on which the analysis is based; the hardware that has been included and excluded from the analysis and the rationale for the exclusions. The ground rules also describe the indenture level of the analysis (i.e. the level in the hierarchy of the part to the sub-system, sub-system to the system, etc.), the basic hardware status, and the criteria for system and mission success. Every effort should be made to define all ground rules before the FMEA begins; however, the ground rules may be expanded and clarified as the analysis proceeds. A typical set of ground rules (assumptions) follows: [4] Only one failure mode exists at a time. All inputs (including software commands) to the item being analyzed are present and at nominal values. All consumables are present in sufficient quantities. Nominal power is available Benefits Major benefits derived from a properly implemented FMECA effort are as follows: It provides a documented method for selecting a design with a high probability of successful operation and safety. A documented uniform method of assessing potential failure mechanisms, failure modes and their impact on system operation, resulting in a list of failure modes ranked according to the seriousness of their system impact and likelihood of occurrence. Early identification of single failure points (SFPS) and system interface problems, which may be critical to mission success and/or safety. They also provide a method of verifying that switching between redundant elements is not jeopardized by postulated single failures. An effective method for evaluating the effect of proposed changes to the design and/or operational procedures on mission success and safety. A basis for in-flight troubleshooting procedures and for locating performance monitoring and fault-detection devices. Criteria for early planning of tests. From the above list, early identifications of SFPS, input to the troubleshooting procedure and locating of performance monitoring / fault detection devices are probably the most important benefits of the FMECA. In addition, the FMECA procedures are straightforward and allow orderly evaluation of the design.

19. HAZARD SURVEYS

20. Figure 11-3

21. FAILURE MODE AND EFFECTS ANALYSIS Failure Mode and Effect Analysis (FMEA) is a systematic approach to evaluate a process in order to identify the relative impact of different failures and the need to identify the parts of the process that need to be changed. FMEA includes a review of the following:  Steps in the process FMEA Failure modes (What can go wrong?) Failure causes (Why will the failure happen?) Failure effects (What will be the consequences of each failure ? Teams often use this model to identify failures and take measures to improve and prevent these. This emphasis on prevention may reduce the risk of harm to both patients and the staff as well. 

22. How to Perform Failure Mode and Effects Analysis? Conducting a Failure Mode and Effect Analysis involves the following steps:  Step 1: Identify potential failure and effects The first FMEA step is to analyze functional requirements and their effects to identify all failure modes. Failure modes in one component can lead to failures in others. Examples of failure effects include overheating, noise,  abnormal shutdown, and user injury. Step 2: Determine severity Severity is the seriousness of failure consequences of failure effects. Usual rates of failure affect severity (S) on a scale of one to ten, where 1 is the lowest severity and 10 is the highest.  Step 3: Gauge chances of occurrence   Examine the reason behind the failure and the number of occurrences. At this step, it is important to determine all the causes of failures.  Step 4: Failure Detection  After the improvement plan has been analyzed , it should be checked for its efficacy and accuracy. This step detects failures, if present, at an early stage.  Step 5: Risk priority number (RPN) RPN is used to measure the risk priority scale. The formula for performing RPN is :  RPN= S×O×D  where S= Severity O = Occurrence D = Failure detection 

23. Benefits of Implementing Failure Analysis Implementing Failure Mode and Effects Analysis (FMEA) offers various benefits to organizations across various industries:  This systematic and proactive approach to identifying and reducing failures contributes to improved processes, product quality, and overall business resilience.  FMEA is a risk management tool. By systematically analyzing failure modes and their outcomes, organizations can identify and prioritize risks.  This method allows for the implementation of measures to reduce the likelihood and impact of failures, minimizing business risk. Addressing potential failures in the development or operational phase is more cost-effective than dealing with issues later.  FMEA helps organizations identify and mitigate risks before they lead to failures, reducing the need for expensive actions and preventing financial losses. In industries where safety is important, such as manufacturing and healthcare, FMEA plays an important role in identifying failures that could compromise safety.  Addressing these failures proactively helps organizations create safer environments for both employees and end- users.FMEA   provides insights into process weaknesses and inefficiencies. Organizations can use FMEA results to optimize their processes and improve overall operational efficiency. This process can be used to assess and improve the reliability of suppliers.  By understanding potential failure modes in the supply chain, organizations can collaborate with suppliers to enhance the overall quality and reliability of materials and components.

24. Important Questions on UNIT- IV Q.1 What are the check lists for Hazard Analysis? or, What is the utility of Process Hazard Check lists? or, Give a typical Check list illustrating how hazards can be pin pointed and highlighted. or, What are the different types of hazards involved in an Ammonia Plant with natural gas as the raw material? List them Q.2 What is Fault Tree Analysis ? Explain Q.3 What is HAZOP Study ? or, What are the guide words used in a HAZOP study ? Give their meanings and comment on them.

25. Important Questions on UNIT- IV

26. Important Questions on UNIT- IV

27. Important Questions on UNIT- IV