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Safety Hazards
Ching, Warren
Cu, Joshua
Javier, Mike
So, Jonathan
Uy, Jeckson
Introduction
Process and Plant Safety Hazards
Process and Plant Safety
Hazards
Involves the application of scientific,
engineering, and management principles.
Delphi Method
- ranks the hazards according to their
probable occurrence and severity.
Risk analysis and
Management
1. All practical steps should be made to
reduce both the probability and severity of
the risk
Regulatory requirements
Reactivity data
Health information
What-if
Check list
What-if/Check list
Hazard and operability study (HAZOP)
Failure mode and effects analysis (FMEA)
Fault tree analysis
Appropriate equivalent methodology
What-if
brainstorming techniques, in the form of ‘What If’
questions are used to identify possible deviations
and weaknesses in design.
‘What If’ hazard analyses can be used to determine
system compliance with SEMI S2 requirements to
verify that “no single point of failure or operational
error should allow immediate exposure of personnel,
facilities or community to hazards or directly result in
injury, death or equipment loss.”
What is SEMI S2 Requirements?
(FMEA)
Begins of all listing the Equipments and
process components of the system under
study
More applicable to projects that are well into
design phase.
Contains failure mode, consequences,
safeguards, recommended action
Fault Tree Analysis
TOP
Transfer IN-OUT OR GATE AND GATE
EVENT
BASIC UNDEVELOPED
EVENT EVENT
Fault Tree Analysis Example
SYSTEM
FAILS
C D
A B
Personnel Motivation and
Training
Operations and Maintenance Personnel
needs training
Highly trained and skilled personnel are
excellent resource for improving safety and
productivity.
Outside contractors are also to be considered
Well-conceived process control system
should reflect a balance between:
Human Control
Reflects human capability at a particular time when the
response is required
Hardware Control
Reflects upon the hardware design and mechanical
integrity at a particular point of demand
Human Errors
Errors of Omission
Employee forgot to execute a required task
Errors of Commission
Employee Performed the task but did it incorrectly
Errors of Sequence
Employee did the task out of order with the required
sequence
Errors of Timing
Employee did the task either too fast or slow
Operator-Induced Error
Employee has the knowledge to make the correct
decision but acts incorrectly
System-Induced Error
Created by integration of incompatible
components into a total system
Design-Induced Error
Results from faulty equipment design, fabrication
or installation
Input Errors
Caused by typographical errors associated with
data or information
Low Stress Errors
Cause by a lapse of memory during a normal
environmental condition
High Stress Errors
When employees make wrong decisions in
life-threatening situations
Process and Plant Modification
Change
It should not result in errors that could lead to
accidents