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Industrial Safety Evaluation Tools

This document discusses relative ranking techniques for evaluating process safety hazards. It describes the Dow Fire and Explosion Index, which considers factors like material properties, process conditions, and safety systems to assign a relative risk index to process units. The document also outlines what-if analysis, which identifies potential hazards, accidents, and consequences through a team brainstorming approach to evaluate safety levels.

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278 views16 pages

Industrial Safety Evaluation Tools

This document discusses relative ranking techniques for evaluating process safety hazards. It describes the Dow Fire and Explosion Index, which considers factors like material properties, process conditions, and safety systems to assign a relative risk index to process units. The document also outlines what-if analysis, which identifies potential hazards, accidents, and consequences through a team brainstorming approach to evaluate safety levels.

Uploaded by

jeevanantham 5846
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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RELATIVE RANKING TECHNIQUES

 Because process areas can be ranked in terms of


the hazards they present, methods which allow
Safety this to be done without a detailed risk analysis are
Reviews
called Relative Ranking Techniques.
Relative
ranking
technique 1. Dow Fire and Explosion Index
2. Mond Index
3. Substance Hazard Index
4. Material Hazard Index
5. Chemical Exposure Index
6. Threshold Planning Index
Relative Ranking Techniques
 Dow Fire and Explosion Index
Considers factors involving material properties,
Safety
process conditions, operating characteristics,
Reviews
safety and fire protection systems and other
Relative
ranking aspects, in arriving at an index, for each process
technique
unit, that characterizes the fire and explosion risk,
 Mond Index
An extension of the DOW F&EI to enable a wider
range of processes and properties, as well as
aspects of toxicity to be covered.
 Substance Hazard Index
This index addresses the risks associated with
toxic vapour releases.
Relative Ranking Techniques
 Material Hazard Index
An index based on material vapour pressure and a
Safety
level of concern related to toxicity, flammability,
Reviews
explosivity etc., used to determine threshold
Relative
ranking quantities of materials above which a risk
technique
management program is required.
 Chemical Exposure Index
An index, developed by Dow Chemicals, that
defines the risk of material releases, based on
toxicity, volatility, molecular weight, various
process parameters and distance to area of
concern.
Dow Fire and Explosion Index (FEI)
 FEI is a leading hazard index methodology
recognized by the chemical industry.
Safety
Reviews  The Dow FEI is a ranking system that gives a
Relative
ranking
relative index to the risk of individual process units
technique
due to potential fires and explosions.
Fire and
Explosion
Index
 It serves as a guide for the selection of fire and
explosion protection methods.
Dow Fire and Explosion Index (FEI)
 It assists in determining the spacing between
adjacent unit process.
Safety
Reviews  It is a guide for insurance agencies to set insurance
Relative
ranking
rates.
technique

Fire and  It ranks individual process units where special safety


Explosion
Index
attention can be focused.
What Does the FEI Consider?

1. Six general process hazards.


2. Twelve special process hazards.
Safety
Reviews
3. Nine process control credit factors.
Relative
ranking
technique 4. Four material isolation credit factors.
Fire and
Explosion 5. Nine fire protection credit factors.
Index
1. General process hazards
 Exothermic reactions.
 Endothermic processes.
Safety
Reviews
 Material handling and transfer.
Relative
ranking
 Enclosed or indoor process units.
technique

Fire and
 Access.
Explosion
Index
 Drainage and spill control.
2. Special process hazards
 Toxic materials.
 Sub-atmospheric pressure (<500 mmHg).
Safety
 Operating in or near flammable range.
Reviews
 Dust explosion.
Relative
ranking
technique
 Pressure.
Fire and
Explosion
 Low temperature.
Index
 Quantity of flammable/unstable material.
 Liquids or gases in process.

 Liquids or gases in storage.

 Combustible solids in storage.


2. Special process hazards
 Corrosion and erosion.
 Leakage – joints and packing.
 Use of fired equipment.
Safety
Reviews
 Hot oil heat exchanger system.
Relative
ranking
technique
 Rotating equipment.
Fire and
Explosion
Index
3. Process Control Credit Factors
 Emergency power.
 Cooling.
Safety
Reviews  Explosion control.
Relative
ranking  Emergency shutdown.
technique

Fire and  Computer control.


Explosion
Index
 Inert gas.
 Operating instruction procedures.
 Reactive chemical review.
 Process hazard analysis.
4. Material Isolation Credit Factors
 Remote control valves.
 Dump or blow down control.
Safety
Reviews
 Drainage.
Relative
ranking
 Interlocks.
technique

Fire and
Explosion
Index
5. Fire Protection Credit Factors
 Leak detection.
 Structural steel .
Safety
Reviews
 Fire water supply.
Relative
ranking
 Special systems.
technique

Fire and
 Sprinkler systems.
Explosion
Index
 Water curtains.
 Foam.
 Hand extinguishers.
 Cable protection.
What-If Analysis
 What-If analysis identifies: hazards, possible
accidents, qualitatively evaluates the
Safety consequences and determines the adequacy of
Reviews
safety levels.
Relative
ranking
technique
 Systematic, but loosely structured, assessment:
Fire and
Explosion
Index  team of experts brainstorming
What-If
Analysis  generate a comprehensive review
 typically performed by one or more teams with
diverse backgrounds and experience
 Applicable to any activity or system
What-If Analysis
 generates qualitative descriptions of potential
problems
Safety  in the form of questions and responses
Reviews

Relative  lists of recommendations for preventing


ranking
technique
problems
Fire and
Explosion
Index

What-If
Analysis
What-If Analysis
Example of What-If analysis: Line/Vessel of hydrogen fluoride
supply system
What If Consequences Safety Level Scenario Comments
Safety
Reviews
Possible rupture
Relative
ranking of HF cylinder with Add pressure
technique …the pressure
personnel alarm on
relief valve None 1
Fire and exposure to HF operator
Explosion
fails ?
and blast effect, console
Index
possible fatalities.
What-If
Analysis
Review training
…the operator records to make
HF release with
does not valve sure all staff
personnel
off the empty None 2 have been
exposure,
cylinder before trained in
possible fatalities.
removing it? current
procedures.
Summary
 Hazard Evaluation Techniques
 Quantitative
 Qualitative
 Safety Review
 Process / System Checklists
 Dow Fire and Explosion Index
 What-If Analysis.

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