Chapter 8A - Safety Evaluation

School of Engineering
DESIGN PROJECT 4170- 2016

CHAPTER 8 - PART A
SAFETY ASSESSMENT
Reference : CHE 4170 2016 Unit Guide
Monash University Malaysia is jointly owned by Monash University and the Jeffrey Cheah Foundation
Weightings for report excluding the 4 interviews

Week
Activity
Report (report mark is 80% of total mark)

Data gathering task (presentation on Moodle)
Task A
Task A
Task A
Task C
Task B
Task B
Task B
Task C
Task C
Task C
Task C
Task C
Task C
Ch1 Problem Definition

Ch2 Process Technology Evaluation & Selection
Ch3 Process Synthesis & Flowsheet Development
Ch4 Mass and Energy Balances
Ch5 Specification of equipment items
Ch6 Detailed Process and Mechanical Design
Ch7 Piping and Instrumentation Diagram
Ch8 Safety and Environmental Assessment
Ch9 Group HAZOP
Ch10 Plant Layout
Ch11 Economic Evaluation
Ch12 Project Viability
Report presentation mark
Value %
Page Limit
3%
3 slides +
References
4%
6%
14%
10%
5%
15%
7%
7%
4%
4%
10%
5%
6%
Total 100%
8
20
30
20
1p/spec
10p/section
2p/section
5p/section
10
8
12
6
300 (max)
23 Sept 2013
CH8: SAFETY EVALUATION

Details of task:
Part A Safety (Individual)

NOTE : No textbook writing , diagrams, materials available within the general HSE fraternity
is allowed. Non- compliance will be subjected to penalty.
This chapter focuses on the detailed design of one section of plant per team member, which is related
to the team members P&ID, (except for the two team members writing Part B).
Each team member (except for the writers of Part B) should identify specific hazards associated with
this section of plant and explain how these hazards are mitigated.
This should include a discussion on inherent safety ie designing out the hazard where possible, safe
operating procedures for this section and include normal operation, start-up, shutdown and operation
during cleaning.
Emergency Response should also be discussed as a form of mitigation.
An bow tree analysis should be conducted, for at least one hazardous scenario identified for the P&ID.
Requirements for specific procedures should be addressed, but detailed procedures are not required.
3
CH8: SAFETY EVALUATION

Details of task:
Part A Safety (Individual)
Identify the nominated section for each member.
Briefly highlight the various process hazards associated with the plant and make references to key
equipment/sections within your work package which are most susceptible to a hazardous event i.e. fire,
explosion, toxic emissions, thermal. Tabulate under Hazards Identified, Causes, Potential Outcomes
and Mitigation Measures
List down the Standard Operating procedures (SOPS) , i.e Start Up, Normal Operation, Shut Down
procedures for the DD item within your work package. Shut down procedures must cover the need to
drain and decontaminate the plant to facilitate maintenance access. Write a brief process narrative for
the section with step wise procedures (systematic and sequential) in bullet point format. Identify
precautions to be taken for the relevant steps. Tabulate.
Prepare a bow tie diagram for a Hazardous scenario, identified for a major operating unit or system
in your section of the plant. (DD item). This could be Major Fire, Significant Leakage, Catastrophic
Failure or a combination of all. You need to be specific about the design and engineering features
associated with that equipment and NOT generic., i.e references to equipment, item tag nos. etc.
4
SAFETY ASSESSMENT AND RISK MANAGEMENT
You need to construct a bow tie for at least

one hazardous scenario on your P&ID
Hint- Look for scenarios with controls or alarms etc.
HAZARDS
What are the hazards in your plant section ?
Chemical properties and conditions
Explosion/Implosion
Release of toxic chemicals
Runaway reactions.
But also think about.
Cold/hot temperature exposure

Mechanical failure
Corrosion
Mixing of incompatibles
Incorrect material selection
Wrong sequence of activities etc
INHERENT VERSUS ENGINEERED SAFETY

Inherent Safety
Avoids the need for hazardous materials
Uses less hazardous materials or lower inventories
Uses them at lower temperatures or pressures
Dilutes them with inert materials
( Eliminate, Minimise, Substitute, Moderate, Simplify )
Engineered Safety
Uses systems (below) to mitigate the risk associated with the
handling of hazardous materials.
Shutdown systems, pressure relief systems, and fire fighting
systems
Absorption, Dispersion, Containment systems

CONTROL MEASURES
Hierarchy of controls
Examples of controls include:
Procedures
Control systems and alarms
Emergency response
Training
Maintenance
Testing
Sarah Sinclair 2014
BOW-TIE DIAGRAM
Pick one major incident for YOUR P&ID

Bow-Ties
How can it happen? Generate a list of hazards
that could lead to your major incident.
What stops the hazard from causing the major
incident ? These are the preventative control
measures.
What outcomes could there be?
What stops or reduces the outcome? These
are mitigative control measures.
CONTROL MEASURES
Bow-Tie
What does the
bow-tie tell you?
Discussion
Does it make sense?
What could be improved/examined in
more detail later? (Hint: are there paths
that
dont
have
enough
control
measures?)
BOW-TIE DIAGRAM
FAULT TREE
Incidents
Causes
(with control
measures)
Proactive or
Preventative
Controls
Sarah Sinclair 2014
EVENT
Outcomes
TREE (with
control
measures)
Reactive or
mitigative
Controls
EXAMPLE BOW-TIE DIAGRAM

Hazards
Corrosion
Consequences
Inspection and
Maintenance
External
Fire
Drains
System
Foam
system
Overpressure
Process
Control
System
Pressure
Relief
System
Vehicle
Impact
Vehicle
Controls
Impact
Barriers
Dropped
Object
Crane
operating
procedures
Ignition
Suppression
Vessel
design
standards
Large Scale
Release from
Pressure
Vessel
Gas
detection
Incident
Preventative Controls
Evacuation
Mitigating Controls
Sarah Sinclair 2014

Remote
isolation
valve
Unignited
near miss
Process
area fire
Site
explosion
and fire
BOW TIE GRAPHIC FOR AMMONIA RELEASE
Source : Safe Work Australia : Guide For Major Hazard Facilities: Safety Case: Demonstrating The Adequacy
Of Safety Management And Control Measures
MITIGATION
Inherent
Procedures
Control Systems and Alarms
Emergency Response
Training
Maintenance
Testing
OPERATING PROCEDURES - START UP

How will your section of the plant be started ?
What are the pre start- up checks to be carried out , i.e proof test of
alarms
Which equipment and systems are turned on first ?
What order of sequence do valves and controls get opened or action
initiated ?
Will alarms need to be on defeat or kept on overide

What other systems have to be checked and performance verified
before plant can be energised ?
What level of maintenance intervention is required for start up ?
OPERATING PROCEDURES-NORMAL OPERATION

How will your section of the plant be normally operated
What are the key parameters to be monitored ; i.e temperatures,
pressures, flowrates, concentrations, amperages, voltages
What critical process control actions have to be monitored ?
What order of sequence do valves and controls get opened or
action initiated ?
What procedures are in place for process deviations
need to be on defeat or over-ridden ?
Will alarms
What maintenance planning systems (MPS) are in place to ensure

operational integrity of the plant ?
OPERATING PROCEDURES - SHUTDOWN

How will your section of the plant be safely shutdown ?
What critical equipment and systems have to be turned off in
sequence ?
What order of sequence do valves and controls get opened/shut or
action initiated/ deactivated ?
What would be the status of alarms ?

What are the venting, purging and absorption requirements ?
What is the status of all utilities ?

What other systems have to be on continued monitoring, i.e inventory,
stock tank levels, container filling, despatches etc. ?
EMERGENCY RESPONSE
A form of mitigation; minimise the consequences. How will your
section of the plant be safely shutdown ?
Emergency Response may include :
Deluge, Absorption, Containment.

Isolation
Evacuation Alarms, muster points, etc
Emergency Responders
to fight fire and attend to
leakages and emissions and rescue victims.
Support from elsewhere, i.e external bodies, local
authorities
Training.
Relationship to environment and the external community.
CHAPTER 8 A - MARKING SCHEME
SECTION
MARKS
Safety Considerations Inherent safety in design and

engineering
10 %
Process hazards, i.e. identification, cause, outcome and control

measures
25 %
Start Up, Normal Operation, Shut Down Procedures.

Readiness for maintenance inspection following shutdown
25 %
Bow Tie Analysis:

Preventive Controls
Mitigative Controls
20%
10 %
Report Clarity
10 %
NOTE TO REPORT CLARITY
A 1.5 spacing, with a font size 12. The minimum margin on the binding
(inside edge) is 3cm.
Reference: Harvard Author (Date) system and list in alphabetical order. Pay
particular attendance to web references and include the date sighted.
Print: Double-sided
Appendices: including any failure scenario and probability tables. It is
suggested that you number the appendices to match each chapter, i.e.
Appendix A8 contains the appendices for Chapter 8
MARKING RUBRICS
1. High Distinction (HD): Demonstrate excellent level of professionalism in

explaining all the salient contents so that readers understand how the process
safety issues,
occupational health and
safety considerations
and risk
management impacts have been addressed.

2. Distinction (D): Demonstrate good level of professionalism in explaining all the
salient contents so that readers have a sound appreciation of the impacts of

safety, occupational health and risk management issues of plant operations
3. Credit (C):Generally described but needs further needs minor improvement to
meet the professional standard

4. Pass (P): Fairly written but lacks the professionalism
5. Fail (F): Not followed the above criteria
THANK YOU

Chapter 8A - Safety Evaluation

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Chapter 8A - Safety Evaluation

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School of Engineering

DESIGN PROJECT 4170- 2016

Weightings for report excluding the 4 interviews

Report (report mark is 80% of total mark)

Ch1 Problem Definition

CH8: SAFETY EVALUATION

Part A Safety (Individual)

Emergency Response should also be discussed as a form of mitigation.

CH8: SAFETY EVALUATION

Identify the nominated section for each member.

SAFETY ASSESSMENT AND RISK MANAGEMENT

You need to construct a bow tie for at least

Chemical properties and conditions

Release of toxic chemicals

But also think about.

Cold/hot temperature exposure

INHERENT VERSUS ENGINEERED SAFETY

Absorption, Dispersion, Containment systems

Pick one major incident for YOUR P&ID

EXAMPLE BOW-TIE DIAGRAM

Sarah Sinclair 2014

BOW TIE GRAPHIC FOR AMMONIA RELEASE

OPERATING PROCEDURES - START UP

Will alarms need to be on defeat or kept on overide

OPERATING PROCEDURES-NORMAL OPERATION

What maintenance planning systems (MPS) are in place to ensure

OPERATING PROCEDURES - SHUTDOWN

What would be the status of alarms ?

What is the status of all utilities ?

Deluge, Absorption, Containment.

CHAPTER 8 A - MARKING SCHEME

Safety Considerations Inherent safety in design and

Process hazards, i.e. identification, cause, outcome and control

Start Up, Normal Operation, Shut Down Procedures.

Bow Tie Analysis:

NOTE TO REPORT CLARITY

1. High Distinction (HD): Demonstrate excellent level of professionalism in

occupational health and

management impacts have been addressed.

salient contents so that readers have a sound appreciation of the impacts of

meet the professional standard

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