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Accident Classification Spills 52% X 11% 30% 56% 3% 100% 37% 53% 10% 100% 5.72% 15.60% 29.12% 1.56% 52.00% Equipment failures Piping failures (especially lined pipe and gaskets) Operational errors, non-compliance with procedures, non-existent procedures Other unspecified
Emissions
30% X
11.10% Piping failure (Lined pipe the largest contributor 15.90% Operational and procedural issues 3.00% Other unspecified 30.00%
Fires
18% X 100%
9.00% During Construction 4.50% Pump Seal Failures 4.50% Engineering and Operations Oversights 18.00% 49.52%
HAZOP =
Page 1
Hazards
From Guidelines for Hazard Evaluation Procedures Accident Sequence Events Process Hazards
CCPS / AIChE
Table 1.3 Guidelines for Hazard Evaluation Procedure by AIChE / CCPS, p-18
Significant Inventories of Flammable materials Combustible materials Unstable materials Corrosive materials Asphyxiants Shock sensitive materials Highly reactive materials Toxic materials Inert gases Combustible dusts Pyrophoric material
Extreme physical conditions High temperatures Cryogenic temperatures High pressures Vacuum Pressure cycling Temperature cycling Vibration / liquid hammering Ionizing radiation High voltage / current Corrosion Erosion
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Hazards
Page 3
Initiating
Table 1.3 Guidelines for Hazard Evaluation Procedure by AIChE / CCPS, p-18
Process Deviations Pressure Temperature Flowrate Concentration Phase / state change Impurities Reaction rate / heat of reaction Spontaneous Reaction Polymerization Runaway reaction Internal explosion Decomposition Contaiment Failures Pipes, seals, vessels, gaskets Equipment failures Pumps, valves, instruments sensors, interlock failures Loss of Utilities Electricity, nitrogen, water refrigeration, air, heat, transfer fluids, steam, ventilation
Management systems failure Inadequate staffing Insufficient training Lack of administrative controls Lack of or poor audits Human errors Design Construction Operations Maintenance Testing Inspection External events Extreme weather conditions Earthquakes Nearby accident impacts Vandalism Sabotage
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Intermed Events
Table 1.3 Guidelines for Hazard Evaluation Procedure by AIChE / CCPS, p-18
Risk reduction factors Control / operator responses Alarms, control system responses, manual / automatic ESD Fire / gas detection system Safety system responses Relief valves, depressurization systems, isolation systems High reliability trips, back-up systems Mitigation system responses Dikes, and drainage, flares, fire protection systems Explosion vents, Toxic gas absorption Emergency plan responses Sirens / warnings, emergency procedures, Personnel safety equipment Sheltering, escape and evacuation External events Early detection, early warning, specially designed structures Training Other management systems
Equipment failures Safety system failure Ignition sources Furnaces, flares, incinerators Vehicles, electric switches Static electricity, hot surfaces Cigarets, lightning Management systems failure Human errors Omission, commission Faulty diagnosis, Decision making Domino effects Other containment failures Other material releases External conditions Meteorology, visibility
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Outcomes
Table 1.3 Guidelines for Hazard Evaluation Procedure by AIChE / CCPS, p-18
Phenomena Discharge Flash and evaporation Dispersion Neutral or buoyant gas Dense gas Fires Pool fire Jet fire Flash fire Explosions BLEVEs Fireballs Confined explosions Unconfined vapor cloud explosions Physical explosions Dust explosions Detonations Condensed phase explosions Missles
Consequences Effect analysis Toxic effects Thermal effects Overpressure effects Damage assessment Community Workforce Environment Company assests Production
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