Risk Assessment
Center for Chemical Process
Safety (CCPS)
For CCPS of the American Institute of Chemical
Engineers we have authored or co-authored a sequence
of books that provide guidance across the spectrum
of safety and risk topics:
- Guidelines for Safe Storage and Handling
of High Toxic Hazard Materials
- Guidelines for Technical Management of
Chemical Process Safety
- Guidelines for Auditing Process Safety
Management Systems
- Guidelines for Implementing Process Safety
Management Systems
- Guidelines for Chemical Transportation
Risk Analysis
- Guidelines for Post-Release Mitigation
- Guidelines for Integrating Process Safety
Management, Environment, Safety, Health, and
Quality
- Guidelines for Selecting the Design Basis
for Process Safety Systems
- Guidelines for Pressure Relief and Effluent
Handling Systems
Refinery Risk Assessment
For a large refinery, we performed a hazard and
risk analysis for an alkylation process unit that
uses liquefied hydrogen fluoride (HF) as the catalyst.
The analysis focused on potential loss-of-containment
accidents associated with the receipt, offloading
of tank cars and storage of HF, the HF alkylation
reactors and processing equipment, and the storage
and loading of spent acids. The risks presented
to workers in the refinery and to persons off-site
were calculated, and the annual probabilities
of occurrence for each event were established
through fault tree analysis. Practical risk control
options were identified, and the risk reductions
potentials were evaluated. The client implemented
several of our recommendations, including installation
of a remotely operated shutoff valve mounted on
the HF storage tank.
Hazardous Materials Transportation
Risk Assessment
On behalf of a major Mexican oil company,
we completed an analysis of the transportation,
loading, and unloading risks for petrochemicals
and liquefied petroleum gases (LPG). The study
included over 250,000 truck, rail, and marine
movements of hazardous materials and a review
of the associated loading or unloading activities
at more than 20 facilities. The movement risks
were analyzed using our transportation risk-screening
model. The facility risks were analyzed using
a risk prioritization matrix and the results of
site visits. Key areas for further evaluation
and several risk reduction measures were identified.
Natural Gas Safety and Code
Compliance Assessment
For a U.S. corporation involved in pipeline transport
of natural gas, we conducted a safety and code
compliance assessment of its facilities, which
included natural and sour gas pipelines, sour
gas treating facilities, natural gas liquefaction
(NGL) extraction facilities, and underground natural
gas storage caverns. The corporation operates
about 12,750 miles of underground pipelines with
a peak daily delivery capacity of 5.4 billion
cubic feet of gas. Sixty compressor stations provide
1.1 million horsepower required to move the gas
through the pipelines. Based on site inspections
of all of the company's unique installations and
a representative number of its common facilities,
we were able to extrapolate the site-specific
findings to the rest of the system. The focus
of the safety effort was to identify acute risks
to company personnel and the general public. The
code compliance review included both company-
and government-mandated codes and standards. For
each area of concern we recommended possible mitigating
measures.
Fire Risk Review
For an international cosmetics firm, we evaluated
the occupancy and potential fire behavior of warehouses
containing aerosol cans with hydrocarbon propellants.
Considerations proposed for improved fire safety
included aerosol segregation, the use of combustible
gas detectors, improved warehouse ventilation,
a reduction in the number of potential ignition
sources, and improved materials-handling techniques.
Liquefied Natural Gas (LNG)
Facility Fire Assessment
For an existing LNG peak-shaving facility on the
East Coast of the United States, we studied certain
aspects of its fire protection for the purpose
of upgrade. In particular, we examined the design
performance of both existing and planned portions
of its water spray systems, as well as the specified
and actual performance of an existing, but deteriorated,
intumescent fire protection coating used on certain
structural steel surfaces.
Assessment of Hazardous Chemical
Releases
For a ship and boat construction facility in the
northern United States, we conducted a work program
aimed at facilitating compliance with Section
303 of the Superfund Amendments and Reauthorization
Act (SARA), which presents the need for a facility
response plan that addresses the risks and appropriate
response measures for releases of extremely hazardous
substances from the facility. Our effort included
a risk screening, during which we identified the
incidents that could release toxic or flammable
materials resulting in hazards from thermal radiation,
overpressure, or toxic or flammable vapor clouds.
Also addressed were the fire protection and emergency
response equipment and programs that would minimize
the probability and/or consequences of such events.
Hazard models were then used to estimate the potential
impacts of the events, both on-site and off-site.
Based on these data, an emergency response plan
was developed which also ensured compliance with
relevant Occupational Health and Safety Administration
(OSHA) regulations that address the health and
safety of emergency response personnel.
Facility & Operational
Reliability Safety Reviews
Semiconductor Facility Reliability
Review
For a world-renowned manufacturer of semiconductors,
we carried out a facility risk assessment of their
clean room operations at one of their principal
facilities. Our study included the identification
of risks to which the clean room operations were
exposed, the prioritization of the risks based
on the likelihood of occurrence and their potential
impact, and the generation of risk control measures
to minimize the risk. Key areas addressed include
HVAC/mechanical systems, electrical systems, hazardous
materials, the industrial waste treatment plant,
fire protection, and external events.
Trading Exchange Operational
Risk Review
For a major world trading exchange, we conducted
a facility risk assessment as the foundation for
the development of contingency planning guidelines.
This effort was an integral part of the development
of a critical system risk management plan. Our
work included the identification, quantification,
and prioritization of risks to various systems
and facilities, recommendation of risk reduction
measures, preparation of guidelines for contingency
planning, and the management of residual risk,
including the definition of key organizational
roles and responsibilities. Specific topical areas
addressed included computer and communications
systems, electrical systems, building support
systems (HVAC, domestic water service, and the
sewage ejector system), fire protection, and physical
security.
Multi-Hazard Identification
and Risk Assessment Project
For the U.S. Federal Emergency Management Agency
(FEMA), we contributed to the Multi-Hazard Identification
and Risk Assessment Project. Our work included
the identification and assessment of technological
hazards such as power failures, fires, and dam
failures that occur as a result of natural events.
The risks were identified and prioritized as a
function of risk. Associated mitigating measures
were also identified and developed.
Accidental Hazardous Materials
Spills
On behalf of FEMA, we investigated the need for
and feasibility of preparing a planning basis
development guide for emergencies associated with
accidental spills or discharges of hazardous materials.
Directed toward state and local emergency preparedness
personnel, such a guide would ideally permit assessment
of the likelihood, nature, magnitude, and consequences
of chemical-related emergencies within any specific
locality or jurisdiction of concern. This information,
in turn, would permit more effective allocation
of resources and better focusing of plans on the
true risks and threats faced by a community.
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Ergonomics
American Chemistry Council
Ergonomics Guide
We developed a Manager's Guide to Ergonomics
in the Chemical and Allied Industries for
the American Chemistry Council. The guide has
been used by many companies to introduce ergonomics
and to create an understanding of the relationship
between improving employee health and safety in
the workplace and measurably improving business
performance.
Ergonomics Site Evaluation
Upon completion of advanced engineering training,
our engineers—working with ergonomists—analyzed
a materials handling operation in a household
products manufacturing plant. A worker had injured
his back lifting a 60-lb. box (with a coworker)
from floor height approximately 80 to 100 times
per day. Upon installation of an air hoist, a
two-person lift was reduced to one-person lift,
and 12 minutes per day were saved through elimination
of excessive handling.
Oil Field Mechanics Ergonomics
Evaluation
For a multinational petrochemical company, we
evaluated hazards and developed practical solutions
for oil field mechanics jobs that had resulted
in musculoskeletal injuries. We conducted training,
analyzed, and provided recommendations to reduce
the forces associated with a gasket replacement
operation. We reduced the number of parts from
which removal was required during pump maintenance
by 25 percent, and reduced the time required for
maintenance by 50 percent. The client projected
that the improved technique will save approximately
52 days of work per year.
Ergonomics Assessments and
Design Evaluations
For various chemical companies, we conducted a
wide range of assessments and design recommendations,
including:
- Analyzed and made recommendations in a materials
handling operation for a moist chemical product.
A platform modification to the material container
allowed better access and reduced bending and
overhead reaching.
- Analyzed pack-out operation in a chemical
processing plant to reduce disc compressive
force to the lower back and to minimize twisting
and bending. Solution designs included installing
a mechanical assist for handling bags and realignment
of a conveyor scale and lift table to minimize
twisting.
- Assessed jobs in a chemical facility, which
was experiencing a high number of injuries related
to materials-handling activities. Recommendations
included raising materials using adjustable
pallets, training employees in proper lifting
techniques, and installing hoists.
- Performed ergonomic evaluation to identify
factors relating to back injuries in shipping
and packaging operations in a chemical facility.
Solutions included repositioning equipment to
reduce excessive reaches, using mechanical assists
to lift pallets, and providing a cutaway hole
on pallets to eliminate high force pinch grips.
- Conducted a baseline screening survey for
materials handling operations for purposes of
prioritizing jobs according to risk factor and
providing general recommendations for implementing
ergonomic solutions.
- Provided recommendations and design criteria
for incorporating ergonomics into the design
of a new control room facility. Recommendations
included installation of proper lighting for
computer use, adjustable seating for workstations,
work surface configuration, and appropriate
spatial arrangements.
- Developed an ergonomics plan with a major
chemical company, provided training for managers,
engineers, and safety professionals at regional
locations and at individual sites throughout
the country.
Safety Improvement
U.S. Environmental Protection
Agency (EPA) Safety, Health, and Environmental
Management Division (SHEMD) Support
We are currently providing technical expertise
to the EPA under the EPA SHEMD contract. We pride
ourselves on the delivery of superior technical
products, which are provided in a timely and cost-effective
manner. For the past several years we have provided
support in the areas of occupational health and
safety; environmental compliance; and pollution
prevention. Occupational health and safety assignments
have included developing a laboratory safety,
health, and environmental management program manual;
facilitating various workshops and conferences;
and developing bomb threat training. Our environmental
compliance work has involved diving safety, and
our pollution prevention work has included review
of the Site Environmental Plan Documents.
Indoor Air Quality Assessment
The administrative personnel of a large southern
medical college were relocated to a renovated
former retail store complex. After nearly three
years of health, moral, and productivity complaints
affecting the staff of approximately 300, the
health and safety program manager contacted us
for assistance in resolving the issue. Much of
the staff attributed their discomfort to the new
building and its air quality. Our investigation
began with a series of conference calls and an
off-site review of the extensive monitoring and
symptom questionnaire data gathered during the
period when the population had reported health
complaints. With a solid understanding of the
historical background, a team consisting of a
facilities management/HVAC expert and an industrial
hygienist spent two days on-site. On-site work
consisted of extensive interviews and inspection.
Our report detailed program management deficits,
as well as design and maintenance issues impacting
the total building environmental quality, and
included cost estimates and a prioritization for
maximum impact.
Noise Assessment
The corporate mail department of a large financial
institution updated sorting and printing machines
and needed to know what the impact would be to
area noise levels. We performed a comprehensive
noise survey that included both personal dosimetry
monitoring and area sampling. A representative
number of workers were selected from each of the
three shifts and personal samples were collected.
Sound contour maps were generated using the data
gathered during area monitoring. The results were
reported along with guidance for the creation
of a facility hearing conservation program and
recommendations for area engineering controls.
Industrial Hygiene Review
A food industry consulting company enlisted
the services of our industrial hygienists to evaluate
the noise exposures generated during operation
of a cereal steam puffer. The noise—characterized
as impact—generated noise levels in excess
of 135 dBA (a widely used decibel level measurement).
An octave band analyzer was used for this evaluation
to allow complete characterization of the noise
and to assist in the selection of sound absorbing
materials.
UMass-Boston Indoor Air Quality
Review
The University of Massachusetts at Boston
(UMass-Boston) was shut down in early 1994 after
a series of well-publicized indoor air quality
events. Working initially at short notice over
a holiday weekend, we assembled a highly qualified
team of industrial hygienists, odor analysts,
and ventilation and facilities engineers and technicians
to evaluate the situation. Working within the
highly charged political environment created by
media coverage of the initial campus closing,
we assisted in the effort to reopen the campus
shortly thereafter. The investigation identified
a number of contributing factors in the event.
These factors included a combination of acute
exposures, facility ventilation system maintenance
and design, psychosocial factors, and building
use issues. Working over a period of five months,
we led the effort to solve the various problems,
install a system to monitor for future issues,
and regain confidence in the indoor environment
at the campus.
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