Introduction to Safety, Risk and Reliability Engineering

Hazard Management in Design

Hazard Management in Design

• What is design?
• Impacts on design; schedule, budget, leadership & culture
• The stages of a project
• Hazard management strategy - overview
• Hazard identification
• Hazard screening
• Hazard gradient

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 Introduction to Safety, Risk and Reliability Engineering
Hazard Management in Design

What is design?

We can consider Engineering Design to be the

combination and interplay of engineering and
management disciplines to achieve a product
that performs to meet expectations.

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 Introduction to Safety, Risk and Reliability Engineering
Hazard Management in Design

Interplay of disciplines for large projects

Co-ordination and appreciation required between

all technical, commercial and management disciplines.

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 Introduction to Safety, Risk and Reliability Engineering
Hazard Management in Design

Impacts on Design

• Technical Rigour & Quality

• Schedule
• Budget
• Leadership & Culture

And therefore, impacts on the management of Hazards

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 Decommissioning (Get rid of it!)
& removal

Modifications, (Fix it, change it!)

maintenance and repair

Operation (Keep it running!)

Hook-up and commissioning (Make it go!)

Construction and installation (Build it!)

Detail design (Make it work!)

Front end engineering design (How will it work?)

Conceptual design (What will work?)

Feasibility studies (What could work?)

Exploration and drilling (What will we find there?)

Block bidding
& license application
(Where will we be working?)

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 Make it work!
Detail Design
Specify & purchase ready for
fabrication & operation

Main Safety Activities at this Phase: Engineering & analysis confirms ALARP has been achieved

How will it work?

FEED
Confirm characteristics of chosen concept
plus some early procurement

Main Safety Activities at this Phase: HAZID, HAZOP plus engineer safety systems to meet ALARP demonstration

What will work?

Conceptual Design
Develop and justify selected concept

Main Safety Activities at this Phase: Early HAZID and risk assessment for ALARP demonstration

What could work?

Feasibility Studies
Develops a range of options

Main Safety Activities at this Phase: Coarse risk ranking of potential development options

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 What could work?

Feasibility Studies
Develops a range of options

Main Safety Activities at this Phase: Coarse risk ranking of potential development options
Main Players active at this Phase: Duty Holder, DTI
Subsidiary Players: Front-End Consultants

• Basic development options identified

• Coarse risk ranking of development options
• Cost
• Weight
• Development schedule

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 What will work?

Conceptual Design
Develop and justify selected concept

Main Safety Activities at this Phase: Early HAZID and risk assessment for ALARP demonstration
Main Players active at this Phase: Duty Holders, Front-End Consultants/Design Contractors
Subsidiary Players: HSE,Verification Body and Specialist Consultants

• Identify design options

• Select concept (using inherent safety principles)
• Demonstrate selected concept is ALARP

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 How will it work?
FEED
Confirm characteristics of chosen concept
plus some early procurement

Main Safety Activities at this Phase: HAZID, HAZOP plus engineer safety systems to meet ALARP demonstration
Main Players active at this Phase: Duty Holders, Design Contractors, HSE,Verification Body
Subsidiary Players: Specialist Consultants, Other Contractors (e.g. Drilling etc.)

• Identify and assess major hazards

• Identify and assess other hazards
• Eliminate and prevent hazards
• Set Performance Standards
• Iterate risks through ALARP process

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 Make it work!
Detail Design
Specify & purchase ready for
fabrication & operation

Main Safety Activities at this Phase: Engineering analysis confirms risks are ALARP
Main Players active at this Phase: Duty Holders, Design Contractors, HSE,Verification Body
Subsidiary Players: Specialist Consultants, Other Contractors (Drilling etc.)

• Confirmation of assessment of major hazards

• Confirmation of assessment of other hazards
• Reduce and mitigate hazards
• Confirmation of Performance Standards
• Confirm risks are ALARP

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 Introduction to Safety, Risk and Reliability Engineering
Hazard Management in Design

Hazard Management Strategy – Overview (1)

1. Identify hazardous events

(start with coarse assessment and carry out iterations in more detail at suitable stages).
2. Analyse and assess the hazardous events
(by type, areas affected, magnitude of the consequences, duration, likelihood, etc.).
3. Reduce the risks from fires and explosions
(primarily through inherently safer design).
4. Implement protective design features
(to reduce the likelihood, scale, intensity, duration and effects).

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 Introduction to Safety, Risk and Reliability Engineering
Hazard Management in Design

Hazard Management Strategy – Overview (2)

5. Identify and specify protective measures
(that is the prevention, detection, control and mitigation measures).
6. Confirm the suitability and effectiveness of protective measures selected
(compare to performance standards).
7. Communicate the requirements and specifications required to others
(document, distribute update etc.).
8. Verify the analyses, assessments and performance of the protective measures adopted
(part of verification of performance standards).
9. Document studies, engineering measures and operating assumptions
(including proposed Emergency Responses).

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 Introduction to Safety, Risk and Reliability Engineering
Hazard Management in Design

Hazard Identification: HAZID & HAZOP

The HAZID (Hazard Identification study):
• Looks at external events that can affect the plant or platform
• Carried out as a team-based guideword-directed brainstorming
• Carried out early in the design phase (on preliminary layouts)

The HAZOP (Hazard & Operability study):

• Looks at process upsets and operating difficulties (inconveniences)
• Also carried out as a team-based guideword-directed brainstorming
• Now very widely adopted and can be used retrospectively

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 Introduction to Safety, Risk and Reliability Engineering
Hazard Management in Design

Screening process:

The Process Design Spiral or Inherent Safety

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 Enhanced
monitoring
requirements

More
maintenance
More complexity, intervention
more leak sources

More
Duplication to instrumentation
increase /automation
redundancy

More
safety
systems

The process design spiral

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 Reduced
monitoring
requirement

Reduced complexity, Less instrumentation,

fewer leak sources less automation

Reduction,
Less maintenance, reduced inventories
less intervention

Increased Elimination,
robustness attenuation,
substitution

Inherently safer design cycle

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 These areas
must be as
safe as
reasonably
practicable

This area can

be allowed to
contain more
hazardous
equipment

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 Firewater tanks
Fire
water Local Control Room
pumps

This area must be as safe as reasonably practicable

Oil Storage Tanks
Utilities Power Generation

This area can be allowed to contain

more hazardous equipment

Gas Re-Injection Oil Export Process Trains

Bulk
Chemical
Storage

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 Introduction to Safety, Risk and Reliability Engineering
Hazard Management in Design

Definition of Technical Performance Standards

Risk Based Performance Standard

A high level statement of numerical risk, or if a semantic definition, statements of conditions
of unacceptable risk.

Scenario Based Performance Standard

Descriptions of the hazardous scenarios unique to the site or installation that create the
risk.

System Based Performance Standard

The definitions of performance of systems required to act in some protective way in the
event of the hazard being realised.

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 Introduction to Safety, Risk and Reliability Engineering
Hazard Management in Design

Attributes of System Based Performance Standards

Functionality

Availability/Reliability

Survivability

Interaction/Dependencies

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Barriers to escalation (Safety Critical Elements)
with appropriate Performance Standards

Emergency Response alternatives

and further escalation
(make use of ETA)

Major
Accident

Bow-Tie Diagram

Unwanted Top Events triggering or adding to escalation

identify by HAZID/ENVID/HAZOP/PHA and assess by FTA

Life saving features each with appropriate

Performance Standards – confirm performance by
Emergency Systems Survivability Analysis (ESSA)
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