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Ebook: Common Process Hazards |
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This ebook is also a great reference if you are looking for ideas for Safety Moments and Lunch & Learns. A free download of the first four pages is available here. OverviewProcess Hazards Analysis (PHA) is a core
feature of all process safety management (PSM) programs on the
grounds that, "if you don’t know what your hazards are you can’t fix
them". Over the years many PHA techniques have been developed to
help identify hazards. They include HAZOP (Hazard and Operability
Studies), FMEA (Failure Modes and Effects Analysis), What-If
Analysis and the Bow-Tie Technique. Generally these methods require
that a small group of experts from multiple disciplines and
functions identify the hazards associated with the process and then
determine the consequences and likelihoods of those hazards. (These
techniques are described in detail in the book
Process Risk and Reliability
Management.) Yet most process facilities are not unique; technologies, equipment types and management styles tend to quite similar from plant to plant and from company to company. Hence many hazards are much the same, regardless of the specific facility being analyzed. Hence the results of a hazards analysis on one facility should be relevant to other facilities of the same type. This ebook identifies some of the more commonly-identified process–related hazards on process facilities. They are organized into the following categories:
Incidents on a process facility are almost always caused by hazardous and/or flammable materials being released from piping or vessels. Such leaks can be caused either by pipe/equipment failure (usually due to corrosion) or high pressure (with a simultaneous failure of the pressure relief system). Therefore most of the failure scenarios listed above are merely steps on the way to an ultimate ‘Loss of Containment’ situation. BlogA blog to do with Common Process Hazards Analysis is available here. Please add your thoughts and comments to do with this topic. Contents
Introduction
Citations Process Hazards High Flow Erosion Static Electricity Low Flow No Flow Reverse Flow Misdirected Flow High Pressure External Fire Blocked-In Pump / Compressor Utility Failure Loss of Cooling Capacity High Heat Input High Vapor Input Low Pressure High Temperature Low Temperature High Level Wrong Composition Light Hydrocarbons Heavy Materials Incorrect Ratios Polymerization Hazards of Utilities Electrical Power Failure Reverse Flow to a Utility Header Survivability of Utilities Heat Exchanger Tube Leak Hazards of Water Water in Hydrocarbon Tanks Water in Very Hot Liquid Water and Firefighting Firewater and Jockey Pumps Hazards of Steam Reboiler Leak Steaming Vessels during Turnaround Wet Steam Hazards of Ice Line Freezing Hydrates Hazards of Compressed Gas Gas Cylinders Pigging Incident Hazards of Chemicals Carbon Monoxide (CO) Nitrogen (N2) Sulfur Dioxide (SO2) Hydrogen Sulfide (H2S) Hazards of Air Flammable Mixture Blowing a Line Clear External Events Flooding Lightning Earthquakes Hazards of Equipment and Instruments Furnace Firing Fired Heater Burnout Multiple Uses of Equipment Distributed Control Systems Hazards of Piping Hydraulic Hammer Pig Launchers and Receivers Vents and Bleeders Pressure in Relief Headers Overload of Overhead Vacuum Lines Underground Piping Pipe Class Transition Hazards of Hoses Hoses and Truck Pull-Away Hose Run Over Hose Failure Backflow Preventers Hazards of Valves Critical Control Valves in Manual Check Valves Block Valves SDV Bypass Hazards of Pressure Relief Systems Blocked-In Pressure Relief Valve Block Valves below Relief Valves Vent or Header Pressure Shared Relief Valve Publishing and Purchasing Details
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