Practical Approach to Hazard Identification for Operations and Maintenance Workers

THE CENTER FOR CHEMICAL PROCESS SAFETY (CCPS) was established by AIChE in 1985 to study and develop engineering and management practices that help prevent or mitigate catastrophic process safety accidents. CCPS publications provide the latest guidelines for the production, storage, and handling of flammable, explosive, and reactive materials. With the help of CCPS, companies can operate facilities safely and measure their own practices against today's most accepted industry practices.

"This book comes with a CD-ROM which includes a variety of helpful resources, including additional pictures, special hazard identification presentations, worksheets, and checklists. Moreover, case studies show how the concepts and techniques discussed in the book can be applied in real-world situations." (RoSPA Occupational Safety & Health Journal, 1 April 2011)

• Preface xiAcknowledgment xiiiItems on CD xv1 INTRODUCTION i1.1 Intended Audience 91.2 How to Use This Book 111.3 References 122 BASIC CONCEPTS 132.1 Hazard and Risk 142.2 Accident Model 162.3 Physical and Process Hazards 172.4 Benefits of Hazard Identification 342.5 Hazards Types by Industry 342.6 References 433 IDENTIFY HAZARDS 453.1 Concept of Recognition 503.2 Basic Human Senses 513.2.1 Vision 533.2.2 Hearing 683.2.3 Smell 733.2.4 Touch 743.2.5 Taste 763.3 Relationship Between Senses and Higher Order Processes 763.4 Influence of Human Capabilities and Limitations on Hazard Identification 793.4.1 Visual Detection 793.4.2 Sound Detection 813.4.3 Odor Detection 813.4.4 Touch Detection 823.4.5 Hazard Recognition 823.5 What Causes Hazards? 843.5.1 Example 1 843.5.2 Example 2 873.5.3 Example 3 893.6 References 904 TYPES OF HAZARDS 934.1 Explosion Hazards 954.1.1 Reactive Explosion Hazards 954.1.2 Flammable Explosion Hazards 984.1.3 Physical Explosion Hazards 1014.2 Chemical Hazards 1054.2.1 Toxic Chemical Hazards 1054.2.2 Fire Hazards Ill4.2.3 Corrosive Chemical Hazards 1164.3 Electrical Hazards 1184.3.1 Shock/Short Circuit 1184.3.2 Fire 1214.3.3 Lightning Strikes 1224.3.4 Static Electrical Discharge 1224.3.5 Loss of Power 1234.4 Excavation Hazards 1244.5 Asphyxiation Hazards 1264.6 Elevation Hazards 1274.7 Thermal Hazards 1304.7.1 Heat 1304.7.2 Cold 1324.8 Vibration Hazards ..1324.9 Mechanical Failure Hazards 1334.10 Mechanical Hazards 1344.11 Corrosion Hazards 1354.12 Noise Hazards 1374.13 Radiation Hazards 1384.13.1 Ionizing Radiation Hazards 1384.13.2 Non-ionizing Radiation Hazards 1394.14 Impact Hazards 1404.15 Struck Against Hazards 1424.16 Visibility Hazards 1434.17 Weather Phenomena Hazards 1444.17.1 Temperature Extreme Hazards 1444.17.2 Hurricane 1474.17.3 Flood 1474.17.4 Wind 1494.18 References 1495 EVALUATE HAZARDS 1515.1 Field Surveys 1545.1.1 Behavior Observation 1545.1.2 Facility Walkthrough Checklists 4585.2 Pre-Job Assessments 1645.2.1 Job Hazard Analysis 1645.2.2 Pre-Job Planning and Permitting 1755.2.3 Ad Hoc Risk Assessment 1765.3 Facility Assessments 1825.3.1 Preliminary Hazard Analysis 1825.3.2 Critical Task Identification Analysis 1905.4 Incident and Near-Miss Reporting 2015.4.1 Hazard Trending and Analysis 2025.4.2 Hazard Mapping 2045.5 Hazard Identification and Analysis Training 2065.6 References 2076 MAKE RISK-BASED DECISIONS 2116.1 Hazard Ranking 2156.2 Understanding Risk 2176.3 Risk Ranking 2186.3.1 Severity 2226.3.2 Hierarchy of Safeguards or Layers of Protection 2236.3.3 Likelihood 2286.3.4 Risk Ranking 2306.3.5 Example 1 - Flammable/Explosive Hazard 2316.3.6 Example 2 - Flammable Hazard 2346.3.7 More Detailed Matrices 2386.3.8 Similarities Between More Sophisticated Process Hazard Evaluation Techniques 2386.4 References 2407 FOLLOW-UP AND CALL TO ACTION 2417.1 Safety Culture 2427.2 Management Commitment 2437.3 Employee Ownership 2437.4 Implement an Effective Hazard Management Program 2457.4.1 Written Procedures and Training 2457.4.2 Resolving Recommendations for Risk Reduction 2457.4.3 Concepts to Strengthen Protective Systems 2477.5 Hazard Communication 2497.6 Call to Action 2517.7 References 2528 LEARNING AND CONTINUOUS IMPROVEMENT 2538.1 Case Study - Oil Refinery Fire, 2007 2538.2 Importance of Managing Change 2568.3 Published Accident Databases and Resources 2618.4 Revitalizing Lessons Learned 2628.5 Transfer of Knowledge 2638.5.1 Identifying and Collecting Information 2648.5.2 Storing Information 2648.5.3 Transferring Information 2658.5.4 Managing the Process 2658.5.5 Applying What You've Learned 2658.6 Learning from Incidents 2678.7 References 269List of Figures 271List of Tables 277Index 278