Risk Assessment within Production Operations HSE - 08-22

 

 

Course Description

 

The escape of toxic methyl isocyanate vapour from the Union Carbide India Limited plant at Bhopal in India on December 1984 was the most serious process plant incident in history, causing thousands of deaths and many tens of thousands of severe injuries, many of them causing permanent incapacity. This and the explosion at the Phillips Petroleum polyethylene plant at Pasadena on 23 October 1989, which killed 23 people and injured hundreds more, alerted management and governments to the need for much more than traditional occupational safety and health programs to provide safety for those working in, or living around, process plants.

Loss prevention is not only concerned with incidents that cause injury to people. It covers all forms of loss, including damage to the environment and property, and interruption to production caused by major failures of a plant, even when there is no injury to people or damage to the surroundings. Avoidance or minimization of the risks of all these types of incident is embraced by the field of Industrial Plant Risk and Reliability Management.

There are many reasons why organizations may be concerned with managing their risks. These range from avoidance of injury or the cost of replacing damaged equipment, to such matters as maintaining a good public image or avoiding legal claims or prosecution of senior managers for negligence.

This course is designed to cover latest techniques in risk management (the systematic approach to identifying hazards, assessing the risks from each, and targeting resources to prevent accidents), and reliability management in industrial plants.

Course Objectives
Upon the successful completion of the course, participants should be able to:

• Understand the consequences of major accidents in terms of fire, explosion, toxic releases and their costs.
  
• Recognize the difference between hazard, risk and risk management.
  
• Identify hazards, evaluate levels of risk, and use a standardized rating process.
  
• Understand and implement risk assessment techniques in process industry.
  
• Identify frequency of risk assessments, schedule them, and identify who should conduct risk assessments & management
  
• Understand the root cause analysis and provision of examples of actual incidents.
  
• Utilize the quantified risk assessment “QRA” technique.
  
• Utilize the risk and cost-benefit analysis resource allocation for production, maintenance and safety.
  
• Apply the advanced risk management techniques to new projects and current activities.
  
• Develop a strategy for planning and implementing risk reduction action plans.

Who Should Attend

This training program is intended for all safety and reliability management specialists, managers, engineers, and personnel responsible for the safety of the process plant.

• Health and safety practitioners
  
• Engineers
  
• Consultants
  
• Process Controllers
  
• Shift Supervisors
  
• Area Managers
  
• Process Safety Specialists

Training Methodology

This interactive training course includes the following training methodologies as a percentage of total tuition hours:-

50% Lectures
30% Workshops, Group Work & Practical Exercises
20% Videos & Software

Duration: Five days

Competencies:

Provides the necessary knowledge and skill to facilitate PHA Studies. Conduct successful risk assessment and compile a risk profile

Questions?

Contact: training@istecsafety.com

Course Program

Day 1:

08:30 - 09:00	Registration & Coffee
09:00 - 09:15	Introduction
09:15 - 09:30	PRE-TEST
09:30 - 10:00	Introduction • Management of hazards • The benefits of risk management • Scope of process risk and reliability management • Steps in risk management of a process plant
10:00 - 10:30	Break
10:30 - 11:15	Hazard Identification • Types of Impact and energy • Typical types of incident leading to the impact • Types of process plant incidents • Approaches to systematic identification of hazards and risks
11:15 - 11:30	Break
11:30 - 13:15	Ranking and Short-Listing of Risks • The Pareto Principle • Two classes of risks for attention • Ranking the hazards and the associated risk scenarios • Examples of scoring systems for use in rapid ranking
13:15 - 13:30	Break
13:30 - 14:30	Ranking and Short-Listing of Risks (cont’d) • Estimation of the magnitude of the consequences or the frequency, of operational losses • Case studies • Risk management without numbers • Identifying the questions to be answered in the risk assessment
14:30 - 15:30	Lunch & End of Day One

 

Day 2:

07:30 - 08:30	Risk and Reliability Criteria • The problem with “acceptable risk” • Some everyday risks • Risks to members of the public from new plant • Risks to employees • Economic factors in risk criteria • Regulatory approaches to setting risk criteria • Calculating and displaying the risks of potential losses
08:30 - 08:45	Break
08:45 - 10:30	Assessment of the Severity of the Consequences of Hazardous Incidents • Fires • BLEVEs • Vapor cloud explosions • Other explosions • Toxic gas escapes • Environmentally damaging escapes • Assessment of probability of fatality using probit mathematics
10:30 - 10:45	Break
10:45 - 12:30	Assessing the Frequency of Likelihood of Potential Hazardous Incidents or Losses • Analysis of causes of incidents using fault trees • Introduction to reliability mathematics • Quantifying incident frequency on fault trees • Alternative approach to assessing the failure frequency of a system: The cutset approach
12:30 - 12:45	Break
12:45 - 14:30	Assessing the Frequency of Likelihood of Potential Hazardous Incidents or Losses (cont’d) • Assessing the probabilities of various outcomes using event trees • Calculation of reliability of units with installed spares • Availability and modelling the production capability of a plant • Methods of improving reliability of control and protective systems • Sources of failure data
14:30 - 15:30	Lunch & End of Day Two

Day 3:

07:30 - 09:00	Quantitative Risk Assessment: Computer Modelling, Uses in Setting Buffer Zones, Strengths and Limitations, Uses and Abuses • Modelling the risk • Separation distances (or buffer zones) • Some experiences with quantitative risk assessment • Summary of the strengths and limitations of quantitative risk assessment • Applications of hazard analysis and risk assessment • Faults in the application of hazard analysis and risk assessment
09:00 - 09:15	Break
09:15 - 10:45	A Systematic Approach to Risk Reduction • Transferring the risk • Reducing fire risks in process plants • Steps in design of a new plant to maximize fire safety • Case study: upgrading a firefighting water system • Principles of firefighting • Reducing the risks in warehouse operations
10:45 - 11:00	Break
11:00 - 12:30	A Systematic Approach to Risk Reduction (cont’d) • Reduction of risks in transport of hazardous materials • Reduction of BLEVE risks • Reduction of vapour cloud explosion risks • Reduction of toxic gas risks • Reduction of environmental risks of Reduction of the risk of loss of reliability • Design for reliability of control and protective systems • Equipment design for reliability and safety in the oil and gas industry in particular
12:30 - 12:45	Break
12:45 - 14:30	Management of Risk and Reliability of New Plants • Safety, reliability and environmental specification • Safety, reliability and environmental review • Hazard and operability study (HAZOP) • Construction quality assurance and audit • Precommissioning safety inspection • Post-startup Hazop Studies
14:30 - 15:30	Lunch & End of Day Three

Day 4:

07:30 - 09:00	Management of Risk and Reliability of Existing Plants and Operations • Some principles for good management of process safety and reliability • Ongoing monitoring and auditing of process safety and reliability • Some approaches to assurance of effective process risk management • Design of a program for routine monitoring of process risk and reliability
09:00 - 09:15	Break
09:15 - 10:45	Management of Risk and Reliability of Existing Plants and Operations (cont’d) • Auditing • Critically important procedures • Learning from accidents and “near misses”
10:45 - 11:00	Break
11:00 - 12:30	Introduction to the “Human Factor”: Including Safety Culture, Safety Climate, and Human Error • Components of “software” • Measuring the standard software • Effect of software standards on quantitative risk assessments • “Safety culture” and “safety climate”
12:30 - 12:45	Break
12:45 - 14:30	Introduction to the “Human Factor”: Including Safety Culture, Safety Climate, and Human Error (cont’d) • Senior management role in safety climate and culture • Measuring the climate and the culture • Human error
14:30 - 15:30	Lunch & End of Day Four

Day 5:

07:30 - 09:00	Role of the Risk and Reliability Manager • Elements of management • Authority and responsibility for performance • Some management situations and tactics
09:00 - 09:15	Break
09:15 - 10:30	Role of the Risk and Reliability Manager (cont’d) • Line of inquiry for a risk and reliability manager • Dealing with the public • The precautionary principle
10:30 - 10:45	Break
10:45 - 12:15	Lessons from Incidents
12:15 - 12:30	Break
12:30 - 14:00	Case Studies and Worked Examples
14:00 - 14:15	POST-TEST
14:15 - 14:30	Presentation of Certificates
14:30 - 15:30	Lunch & End of Course

 

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