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13
Hazard Study Methodology
(August 1997 Edition)
CONTENTS
PAGE
1.0
INTRODUCTION ...................................................................................................................................................................... 4
1.0.1
1.0.2
1.0.3
1.0.4
1.0.5
1.0.6
Purpose ........................................................................................................................................................................................ 4
Team ............................................................................................................................................................................................. 5
Timing ........................................................................................................................................................................................... 5
Preparation.................................................................................................................................................................................. 5
Documentation .......................................................................................................................................................................... 6
Method .......................................................................................................................................................................................... 6
1.1
1.2
PROCESS DESCRIPTION................................................................................................................................................... 7
1.3
1.4
INCIDENT REVIEW................................................................................................................................................................. 7
1.5
1.6
MATERIALS HAZARDS......................................................................................................................................................... 8
1.6.1
1.6.2
1.6.3
1.6.4
1.7
SAFETY..................................................................................................................................................................................... 13
1.8
HEALTH .................................................................................................................................................................................... 14
1.9
ENVIRONMENT..................................................................................................................................................................... 15
1.9.1
1.9.2
1.9.3
1.9.4
1.9.5
1.10
1.10.1
1.10.2
1.10.3
1.10.4
1.12
1.13
ORGANISATION ................................................................................................................................................................... 19
1.14
1.15
1.16
CONCLUSION ........................................................................................................................................................................ 22
FIGURES
1.1
CHEMICAL HAZARD GUIDE DIAGRAM ..................................................................................................................... 11
1.2
MEANS OF HANDLING GUIDE DIAGRAM ................................................................................................................ 12
1.3
EMERGENCY FACILITIES GUIDE DIAGRAM .......................................................................................................... 21
1.0
INTRODUCTION
1.0.1
Purpose
The purpose of Hazard Study 1 is to ensure that the understanding of the project, the process and the
materials involved is sufficient to enable safety, health and environmental issues to be properly
assessed. It also contributes to key policy decisions (e.g. on siting) and ensures that contacts are
established with the functional groups, site management and the authorities who may contribute to, or
impose constraints upon, the development of the project.
Hazard Study 1 is the first formal hazard study applied to all projects. In the case of new products and
processes, there are benefits in applying the Process SHE Impact Study during development.
Key aspects include:
(a)
Ensuring that there is a clear understanding of the objective and scope of the project.
(b)
Reviewing information on any previous incidents on the plant, process, building, service or
operation being studied, and on those elsewhere which use the same technology.
(c)
Collecting information on the safety, health and environmental hazards of all chemicals and
materials involved (individually and in combination).
(d)
Providing a broad appreciation of the hazards of fire, explosion and harmful releases (e.g.
toxic gases, effluent, radioactivity, biohazards etc.); reviewing the application of the concepts of
inherent safety, health and environmental protection.
(e)
Reviewing the draft 'Environmental Impact Assessment' (see Information for Managers Notes E-016) for the project and ensure that this will cover all relevant on-site and off-site
environmental issues.
In addition, the study helps to ensure that the project meets Company objectives for
environmental performance:
(1)
the use of standards which will meet anticipated regulations in the most
environmentally demanding country in which it operates;
(2)
minimisation of waste;
(3)
energy and resource conservation;
(4)
waste recycling.
(f)
(g)
For all the sites under consideration, reviewing on-site and off-site transport of raw materials,
intermediates, products and wastes; identifying and considering interaction of the project with
other plants, processes, buildings, services and operations both on-site and off-site.
(h)
Considering the human and organisational aspects of the project and its subsequent
operation, including emergency services.
(j)
Reviewing the application of national legislation and considering other aspects of regulatory
approval and consents.
(k)
Setting criteria for safety, health and environmental aspects of the Project to comply with
relevant Company guidance (e.g. on the tolerability of risk and on environmental standards).
(l)
Reviewing the Codes of Practice which will be followed, including those which may be in the
course of development.
(m)
Agreeing the extent and timing of further Hazard Studies and the need for any additional
specific studies or assessments (e.g., Chemical Process Hazards Assessment, Quantified
Team
The team composition should be proposed by the Business and Project Managers and agreed by the
Hazard Study Leader. It normally includes:
(a)
(b)
(c)
Project Manager.
(d)
(e)
(f)
(g)
(h)
(j)
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 Hazard Study 1.
1.0.3
Timing
Hazard Study 1 should start as early as possible in the life of a project. Generally, the business or
project management will have formed a basic idea of the project before appointing the project team
and Hazard Study Leader. Sometimes one or two informal meetings will be required before the formal
Hazard Study 1 to initiate and collect the supporting project studies.
Since Hazard Study 1 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.
In the case of new processes or operations, there are major benefits in considering the hazards during
the early development stages of the project. It is then possible to incorporate the concepts of inherent
safety, health and environment most effectively into the process (see Process SHE Guide 16). In some
cases, a very early Hazard Study 1 may be carried out, concentrating on parts of the process
description and incidents.
1.0.4
Preparation
Before the first formal meeting it is advisable that the project team has been identified and that the
following is available:
(a)
(b)
A process description.
(c)
(d)
(e)
(f)
(h)
ICI'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 concepts of inherent safety, health and
environment (see Process SHE Guide 16). These concepts can be applied particularly effectively at
the early stages of a project and they are, therefore, specially valuable and important at Hazard
Study 1.
Various safety, health and environment/risk assessments may be necessary in conjunction with the
Hazard Studies. General background information and advice on techniques and sources of help are
available in ICI Group SHE Information for Managers Note SHE-005 - Risk Assessment: A Managers
Guide - General Introduction, Methodologies and Contacts.
1.0.5
Documentation
The draft report should be issued as soon as practicable, whilst giving details of the information still
lacking. The relevant actions should be complete before the commencement of Hazard Study 2.
The Hazard Study 1 report should be updated and reissued when all actions have been resolved. A
copy of this report should be filed in the Project Safety, Health and Environment Dossier
(STD/F/01022). A template for the Hazard Study 1 report is shown in STD/F/01025.
1.0.6
Method
Hazard Study 1 meetings are held in which the basic SHE issues are reviewed according to the
established format given below. The documentation should follow the same format. With modern
information technology, areas unanswered during the first meeting can often be pursued and resolved
without recourse to more meetings. However, the final report should be agreed by all members of the
Hazard Study team.
1.1
PROJECT DEFINITION
Designs which will be safe and meet environmental and health standards, require a clear
understanding of the objective of the project and the processes involved.
A definition of the Project should be provided by the Business Manager or the Project Manager. For a
suitable format and contents see PP13 - Appendix A, Section A.1. For example the project definition
may cover:
(a)
Objective.
(b)
Scope:
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(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, e.g., by the Process Engineer, Client Representative or himself. This should also include:
(a)
(b)
(c)
(d)
1.3
CONTROL PHILOSOPHY
The project should have a basic control philosophy addressing:
1.4
(a)
Is the proposed application suitable for the intended type of process control (e.g.,
Programmable Electronic Systems)?
(b)
What type of trip system is proposed and how does it interface with the process control (e.g.,
PES)?
(c)
Is there an existing plant and how does any PES fit in?
(d)
(e)
INCIDENT REVIEW
Initiate a review of any incidents with significant Safety, Health or Environmental effects which have
occurred on similar projects or processes/projects using the same or related technology. This should
cover ICI experience and other known incidents.
Information may have to be sought from third parties such as Regulatory Bodies, other companies or
Science Associations.
The sources of the data which are searched should be recorded.
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.
1.5
INHERENT SHE
GG 17.2 of the Group SHE Standard GS 17 (Product Stewardship) requires that each new process
should be subjected to a study of the SHE impact of its operation. The need for a SHE Impact Study
should be identified early on in a Project and the Study carried out prior to Hazard Study 1. Hazard
Study 1 confirms whether a SHE Impact Study is required, has been completed, and, if not, whether
one is required.
Substitute.
(b)
Minimise.
(c)
Simplify.
(d)
Moderate.
Guidance on the application of inherent SHE is available in Process SHE Guide 16.
1.6
MATERIALS HAZARDS
The purpose is to ensure that the material hazards will be fully understood by the project team and,
subsequently, operating personnel. In cases where large numbers of similar chemicals are involved, it
may be appropriate to group these generically.
1.6.1
Material List
Prior to the first Hazard Study Meeting a list (see 1 of 3 of STD/F/01018 - Materials List) of the
materials, chemicals or substances involved should be produced, e.g., by the Functional Engineer,
Chemist or Client Representative. This should cover:
(a)
(b)
(c)
Emissions from adjacent facilities or materials from elsewhere which may be air borne,
encountered in drains, utilities or in the ground.
(d)
(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)
(g)
When the same material is present in different physical states, it may be helpful to list each physical
state separately.
1.6.2
Chemical Hazards
(a)
Consider the hazards associated with the materials involved in the process. This can be done
using the Chemical Hazards standard form (2 of 3 of STD/F/01018), in conjunction with the
Chemical Hazard Guide Diagram (see Figure 1.1) to identify any need for additional
information on the materials involved. The form should be completed with one of the following
3 responses:
-
The hazards are known (identified clearly in the Hazard Data Sheets) and well
understood by the Hazard Study team, design team, operators and process
management.
1, 2, 3
Numbered reference notes should identify and exemplify not well known
hazards or information that is needed.
Much of the information can be assembled outside the meeting by the Occupational Hygienist,
Environmental Specialist, Chemist or other specialist. In all cases, the form 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 form is to indicate the hazards of the materials used in
the process. For capital projects, the compiled information is used by the design team in
developing the design. For existing processes, the compiled information can be used to
ensure that hazards (both known and possibly unknown [new] due to changes in process
chemistry, operating conditions, materials, equipment or operating procedures) are reviewed.
The adequacy of existing process operating, control, protective or emergency systems and
procedures can then be checked.
(b)
Use the Means of Handling standard form (Part 3 of STD/F/01018) and Means of Handling
Guide Diagram (see Figure 1.2) to determine any special storage, handling, production,
environmental and emergency practices which need to be followed for the materials used in
the process. The early identification of potential difficulties may allow the development of
inherently better ways of achieving the project objectives. The form and resulting notes may
be prepared outside the meeting but should be reviewed by the Hazard Study team.
(c)
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 which has been given to inherent safety, hygiene and environmental
acceptability - see Process SHE Guide 16.
Methods of assessing risks are described in Process SHE Guide 10. For major environmental accident
quantification, refer to E-010 - Safety Health Environment Information for Managers, Guidance on
Environmental Impact Assessment of Major Accidents for CIMAH Safety Reports and other Accidental
Releases.
Where the quantity of material to be handled is not known, the quantity which will cause off-plot effects
should be estimated.
FIGURE 1.1
Explosion &
Flammability
Fire
Deflagration/
detonation
Electrical static
Reactivity/ stability
Immediate health
hazards
Irritant/ corrosive
Sensitizer
Chronic health
hazards
Radiation
Is material radioactive?
Nuisance
Odour
Environmental
Aqueous
Gaseous
Ground
Hazards
Hazardous
breakdown
products
FIGURE 1.2
Storage
Transport
Problems in Handling
Process Conditions
Materials of Construction,
Corrosion/Erosion
Decontamination
Gaseous Emissions
Aqueous Emissions
Flare/Thermal Oxidiser
Quality Control
Emergency Procedures
Area Classification
Provision of Services
Codes of Practice
1.7
(b)
Employee risk.
(c)
(d)
(e)
ICI corporate advice on safety risk criteria is given in Group SHE Information for Managers Note S-003
and the limit values for tolerable risk are summarised below:
Note:
The limit values are indicative, not absolute. They should not be exceeded unless adequate
justification can be demonstrated. In practice, the aim should be to achieve risk levels below the upper
limit as far as is reasonably practicable. Refer to Group SHE Information for Managers Note S-003 for
mode of application, relevant assumptions and adjustments that may be allowable.
(1)
35
10-6/year
(2)
10-6/year
(3)
10-6/year
(4)
100
10-6/year
10
10-6/year
A.
B.
Notes:
(i)
In some cases it may be necessary to assess a proposal/project against a fraction of the limit
as judged appropriate for the circumstances of the particular situation.
(ii)
If the effects of a major accident could be more severe a lower target might be appropriate.
1.8
HEALTH
A draft Occupational Health Statement (OHS) should be prepared as early as possible in the project
and prior to the Hazard Study 1 by an occupational hygienist or other suitably trained person and a
project/plant representative. The content and depth of the statement will depend on the project. See
the Group SHE Information for Managers Note H-009: Occupational Health Statements for New
Projects.
The OHS should identify health hazards resulting from:
(a)
(b)
(c)
Health related ergonomics (manual handling, repetitive movements, posture, visual display
terminals).
(d)
The OHS should consider the health risks which may arise during:
(1)
Construction.
(2)
Commissioning.
(3)
Operation.
(4)
Maintenance.
(5)
Demolition.
The OHS 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.
The draft occupational health statement should be discussed and approved by the hazard study 1 team
and form part of the hazard study report. The hazard study team should agree how the requirements
and actions raised in the draft OHS will be reviewed.
The draft occupational health statement should be reviewed to check that:
(i)
(ii)
The OHS includes criteria and standards for all identified health hazards.
(iii)
All the actions and requirements have been incorporated into the project.
(iv)
(v)
1.9
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. (see Process SHE
Guide 16).
1.9.1
Environmental Statement
An Environmental Impact Assessment (see GS 13 and GG 13.1) carried out before the meeting by, for
example, the Process Engineer, Chemist, Client Representative or Environmental Specialist, should
consider the process route options in the light of the Best Practical Environmental Option (BPEO). The
resulting draft Environmental Statement (for guidance see SHE Information for Managers Note E-016)
should preferably include a simple block diagram or flowsheet showing all effluents and wastes. For
each waste stream listed in the Chemical Hazards form (STD/F/01018), the Environmental Statement
should also identify:
(a)
The treatment options considered and justification of the chosen option; Best Available
Technique Not Entailing Excessive Cost (BATNEEC).
(b)
(c)
(d)
Hazard Study 1 reviews and agrees the Environmental Statement. Have means of waste reduction at
source been adequately considered? Is the impact acceptable?
1.9.2
Loss of Containment
It should be considered if the accidental release of material from any section of the plant, or from any
operation, can give rise to a major environmental accident. Methods for assessment are given in
E-010, Safety Health Environment Information for Managers - Guidance on Environmental Impact
Assessment of Major Accidents for CIMAH Safety Reports and other Accidental Releases.
Some tentative proposals giving severity/tolerable frequency guidelines for environmental incident
assessment are also given in E-010. Any other relevant criteria set by site requirements or by local or
national authorities should be identified. As quantitative assessment of environmental incidents arising
from loss of containment is at a relatively early stage of development and use, the most appropriate
criteria to apply may require discussion with the site/business SHE function.
1.9.3
ICI Objectives
It should be confirmed that the project is compatible with ICI's SHE Challenge 2000 objectives:
(a)
Gain total compliance with local regulations and consents, wherever we operate.
(b)
Continue to meet our high world wide standard for the construction of new plants.
(c)
(d)
(e)
(f)
Environmental Impact
Hazard Study 1 should further consider whether:
(a)
There are any effluents not included on the list considered within the environmental statement.
(b)
The data for the environmental effects of the materials being handled are sufficient for the
project and for ongoing operation.
(c)
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.
(d)
Consideration has been given to the disposal of out of specification, returned or contaminated
material.
(e)
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.
(f)
(g)
Any of the process materials will give rise to environmental problems if there is a loss of
containment.
(h)
(j)
(k)
(l)
Any special mechanisms can result in loss of containment and spread, (e.g., flood, wind,
storm, fire water runoff).
(m)
(n)
(p)
Special measures are required to reduce or monitor fugitive emissions (e.g., leaks from glands
or seals).
(q)
(r)
Agree and record the responsibility for any further Environmental Assessments.
1.9.5
Environmental Criteria
It is important to establish the consent levels for continuous and discontinuous discharges and the
tolerable criteria for major and minor incidents (see 1.9.2) at the start of the project and to obtain the
Gaseous effluents release points and environmental impact, for example end of vent release
levels, allowable ground level concentrations, odour thresholds, background levels and Air
Quality Standards (AQS).
(b)
Aqueous effluents release points and environmental impact, for example end of site drain
release levels, ambient levels and Environment Quality Standards (EQS).
(c)
(2)
(3)
(4)
It is important to establish the consent levels for continuous discharges, etc. and the target criteria for
incidents, at the start of the project and to obtain the support and agreement of local management for
these. Consideration may have to be given to changes in standards likely in the foreseeable future.
1.10
1.10.1
Transport Stages
Consider those factors which 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 minimised:
(a)
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.
(b)
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.
(c)
Review whether the risks arising from the construction/demolition work or from the transport
and storage of hazardous materials could be minimised by the choice of plant location,
material to be transported, etc. A simple diagram showing material and transport movement
may assist.
(d)
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.
1.10.2
Loss of Containment
Consider the potential effect of loss of containment on occupied buildings, (e.g., control rooms,
workshops, offices, laboratories, houses, schools, hospitals, retail and sports centres, etc.). See
Process SHE Guide 6, and national examples eg. UK - CIA Guidance for Location and Design of
Existing Plants
Consider the potential effect of existing plants or operations (both ICI and non-ICI) 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.
1.10.4
Other Considerations
Will normally rare events need to be considered in the project design? For example:
(a)
Subsidence.
(b)
Landslide.
(c)
Dam burst.
(d)
Earthquake.
(e)
(f)
Aircraft crash.
(g)
Storm surge.
(h)
(j)
Flood.
(k)
(l)
Breach of security.
(m)
Lightning.
(n)
(p)
Forest fire.
(q)
Vermin/insect infestation.
Can the construction activity and the associated transport be safely accommodated? Is a separate
study, HAZCON, required? For details see EDG.CON.50.01. Will construction noise/vibration/dust
adversely affect existing operations or adjacent buildings?
1.11
EXTERNAL AUTHORITIES
Consideration needs to be given to the authority approval process. This should involve the full
cooperation of staff with experience of the country in which the plant will be located. Lists of authorities
are available on the SSHE Applications database on Lotus Notes.
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)
(b)
(c)
Will the project change the status of the site under any existing regulation?
(d)
(e)
Are chemicals handled that are controlled by international protocols (e.g., chemical warfare).
What reports and studies will be required for the authorities? For the UK see ICI Engineering
Technology Working Instruction PP.13.01, standard form STD/F/00855
1.12
1.13
(a)
(b)
(c)
(d)
(e)
(f)
Product quality.
(g)
ORGANISATION
In addition to the physical/geographical factors associated with site selection already considered,
assess if it is necessary to review the major organisational and human factors.
Ascertain whether the site/operation unit has an existing and effective Safety Management System.
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.
1.14
(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)
(d)
Have facilities for construction manning been considered, (e.g., medical, hygiene and eating
facilities)?
EMERGENCY FACILITIES
Review the adequacy of site emergency facilities to ensure that these are adequate to meet the needs
of the proposed project.
The Emergency Facilities Guide Diagram (see Figure 1.3), may be used in consultation with site
personnel to ensure a full coverage.
Consider how the personnel will be affected by an emergency. What will they do? How will injuries be
handled? Is there adequate access?
Consider whether there are adequate facilities for handling external emergencies arising from the
transport of hazardous chemicals
Where construction/demolition work is required to interface with existing operating plant, suitable
induction training should be provided for construction supervision and operatives.
S&TIS/11600
1.15
FURTHER STUDIES
Consider and agree what 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.
Examples include:
(a)
(b)
(c)
Area classification.
(d)
(e)
(f)
Cable routing.
(g)
(h)
Lifting equipment.
(j)
Noise.
(k)
(l)
Layout.
(m)
Computer systems.
(n)
(p)
Non-process hazards.
(q)
(r)
Critical machines.
(s)
Business risk.
(t)
(u)
Building risk assessment (see 1.10.2 and Process SHE Guide 6).
(v)
Means of isolation.
(w)
Materials review.
Agree where these techniques are to be applied and ensure that the necessary effort is allocated.
1.16
CONCLUSION
Agree the extent of further hazard studies. If the hazard study process will be curtailed justify and
document the reason.
Agree the responsibility and date for progressing actions.