CBB 40104

Bioplant Design Project 2

(Chapter 5: Process Safety)
Commonly Used Words in Safety

Hazard Risk assessment

• Potential to cause harm • Risk in executing job is
to people & equipment assessed before any job is
started
Risk Control measures
• The likelihood of such • The precautions taken for
occurring doing a job safely, based on
risk assessment
Types of Hazard

Physical Electrical

Mechanical Chemical
Risk Rating

Risk Rating = Frequency X Consequence

Frequency Matrix
Frequency Frequency
Frequency Description
Category Range (per yr)

Anticipated (A)
I or events that might occur several times > 10-2
during the facility’s lifetime
Unlikely (U)
or events that are not anticipated to occur
II during the facility’s lifetime
10-2 – 10-4
(such as a 100-year flood)
Extremely Unlikely (EU)
or improbable events that should not occur
III during the facility’s lifetime
10-4 – 10-6
(such as a design basis accident)

Beyond Extremely Unlikely (BEU)

IV or incredible events
< 10-6
Consequences Matrix
Consequence Description
Consequence
Category
Public Worker

Potential for immediate or long-term Potential for immediate and severe health
health effects, or exceeding the EPA or effects, or long-term health effects or
A DOE exposure/evaluation guidelines
 Radioactive Material Dispersal
disability, or potential for loss of life
 Plutonium Dispersal (mechanical or fire)
(with potential for doses > 25 rem)
 Toxic Material Dispersal > IDLH
 Toxic Material Dispersal > ERPG-2

Potential for long-term disability or severe

Minor injuries with no disability or work
restrictions
 Radioactive Material Dispersal
B (with potential for doses
between 0.1 and 25 rem)
 Toxic Material Dispersal between
ERPG-1 and EPRG-2
injury (non life threatening) from non-
standard industrial accidents
 Radioactive Material Dispersal
(including tritium< 20 g)
 Fire with Toxic Material Dispersal
 Toxic Material Dispersal
(>TLV-TWA or equivalent)

No significant offsite impact

(any release is below acceptable limits)
C  Radioactive Material Dispersal
(but with offsite lifetime doses < 0.1 rem,
in accordance with DOE Order 5400.5)
 Toxic Material Dispersal < ERPG-1
Minor injuries with no disability or work
restrictions
 Mechanically-caused Toxic Material Dispersal (< TLV-
TWA or equivalent)

No Measurable Radiological
D or Toxic Release
No measurable consequences
Hazard Analysis Risk Matrix
1 = High Risk
Frequency Category
Consequence
2 = Moderate
Category 3 = Low Risk
I II III IV 4 = Negligible

A 1 1 2 3 Risk # is relative,
not absolute,
B 2 2 3 4 to allow ranking.

C 3 4 4 4

D 4 4 4 4
Methods of Risk assessment

• Hazard & Operability studies ( HAZOP)

• Hazard Identification ( HAZID)
• Hazard Analysis ( HAZAN)
• Preliminary hazard analysis (PHA)
• Fault Tree Analysis (FTA)
• Failure mode and effect Analysis (FMEA)
HAZOPS Analysis Process
Parameter*

Guide Words

None Prevention/ Action

More Of Deviation Cause Consequence Item
Mitigation
Less Of
Part Of
As Well As
Other
. Consequence,
. Likelihood,
& Risk Ranking

*Covering every parameter relevant to the system:

flow, pressure, temperature, viscosity, components, etc.
HAZOP on Seed Fermenter and Fermenter
Guide Deviation Possible Consequences Action required
word causes
MORE High Use jacketed Results in low Use internal
temperature. vessel. efficiency of heat coils because
removal. have larger
surface area for
heat transfer.
HAZOP on Blending/Storage Tank
Guide Deviation Possible Causes Consequences Action Required
word
NO or Outlet 1. Line fracture Product 1. Check the performance
NOT Flow 2. Line of pump periodically.
blockage 2. Install LOW LEVEL
3. Pump ALARM to warn
failures operator.
3. Install LOW LEVEL
ALARM shut down
pump
MORE OF Flow 1. Valve failure 1. Disturbance 1. Install HIGH LEVEL
2. Pump failure will occur on ALARM
other 2. Extend pump suction
equipment line to above tank
2. Influence the base.
purity of 3. Considered standby
product tank.
HAZOP on Blending/Storage Tank

LESS OF Flow 1. Leaking Reduce the 1. Regular patrolling

2. Level control production and inspection of
system failure rate transfer line
3. Low level 2. Install backup alarm
alarm failure 3. Proper maintenance
Control of Safety Hazards
• Elimination
• Substitution
• Isolation
• Control – Administrative & Engineering
• Personnel Protective Equipment (PPE)
Safety related videos

https://www.youtube.com/watch?v=JplAKJrgyew

https://www.youtube.com/watch?v=YjVOJUrhrJM

https://www.youtube.com/watch?v=c9JY3eT4cdM