HAZARD STUDY 1: REPORTING

Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology – Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology – Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
GBH Enterprises, Ltd.
Process Safety Guide:
GBHE-PGP-009
HAZARD STUDY 1: REPORTING
Process Information Disclaimer
Information contained in this publication or as otherwise supplied to Users is
believed to be accurate and correct at time of going to press, and is given in
good faith, but it is for the User to satisfy itself of the suitability of the information
for its own particular purpose. GBHE gives no warranty as to the fitness of this
information for any particular purpose and any implied warranty or condition
(statutory or otherwise) is excluded except to the extent that exclusion is
prevented by law. GBHE accepts no liability resulting from reliance on this
information. Freedom under Patent, Copyright and Designs cannot be assumed.

HAZARD STUDY REPORT
Project
Title
Doc ref.: Project
file:
Issue
:
Approved for issue by: Date:
Signature:
HAZARD STUDY TEAM:
Hazard Study Leader:
Project Manager:
Functional Engineers:
Operations or Site Representative:
SHE Manager:

CONTENTS:
1.0 Actions Agreed
1.1 Project Definition
1.2 Process Description
1.3 Control Philosophy
1.4 Incident Review
1.5 Inherent SHE
1.6 Materials Hazards
1.7 Safety
1.8 Health
1.9 Environment
1.10 Transport and Siting
1.11 External Authorities
1.12 Design Guidelines and Codes
1.13 Organization
1.14 Emergency Facilities
1.15 Further Studies
1.16 Conclusion
Circulation: Hazard Study Team

1.0 ACTIONS AGREED
1.1 PROJECT DEFINITION
1.2 PROCESS DESCRIPTION
1.3 CONTROL PHILOSOPHY
1.4 INCIDENT REVIEW
1.5 INHERENT SHE
Eight GBHE Process SSHE Questions
1) What alternative routes or processes can be used to allow substances or
solvents of lower impact on man and the environment to be considered?
(2) What alternative routes or processes can be used to minimize the
inventories of hazardous substances?
(3) What alternative routes or processes can be used to make process
conditions as benign as possible?
(4) What is the ultimate fate of all substances used in the process that are not
part of the product?
(5) How will processing stages permit internal recycles with minimum or nil
purges?
(6) Can the effluents be further processed to allow a recycle or a better
means of disposal?

(7) What are the consequences on man and the environment of the release of
any of the materials during processing, transport and storage (including
both normal and abnormal conditions)?
(8) What is the impact on capital and operating costs of lower SHE impact
options and higher safety, health or environmental standards?
1.6 MATERIALS HAZARDS
1.6.1 Materials List
See the Materials List - (Part 1 of 3).
1.6.2 Hazard Data Sheets
All Material Safety Data Sheets are available.
1.6.3 Chemical Hazards
See the Chemical Hazards pro-forma - (Part 2 of 3)
See the Means of Handling pro-forma - (Part 3 of 3)
See the Chemical Interactions pro-forma

Looking for issues regarding process robustness (i.e. an indication of how
sensitive the process is to deviations from the process recipe). Is the reaction
sensitive to:
(a) Agitation failure?
(b) Late or fast dump addition of a reagent?
(c) Cooling failure?
(d) Water ingress?
(e) Level of heating?
(f) Over/undercharge of reagent?
(g) The wrong concentration/grade of material being used?
(h) The wrong ratio of reactants is used?
(j) Addition of a material at the wrong stage?
(k) The order of addition, rate of addition, method of addition of any material?
(l) The order of introduction of functional groups?
(m) Contamination?
(n) Stabilizers?
(p) Change of raw materials?
(q) pH?
(r) Scrubber failure?
(s) Failure of vacuum, nitrogen, air or other gas?
(t) Condenser failure?
(u) Blockages

1.6.4 Loss of Containment
Solids
Gases
Liquids
1.7 SAFETY
Toxic gas emission criteria:
Employee risk criteria:
Off-site individual risk criteria:
Off-site group risk criteria:
Major incident frequency criteria:
See also Section 1.9.3.
1.8 HEALTH
Draft Occupational Health Statement available?
Health hazards from: -
(a) Chemical & biological properties:
(b) Noise & vibration:
(c) Ergonomics:
(d) Radiation:
Construction / Commissioning / Operation / Maintenance / Demolition all
considered?
Criteria & standards established?

1.9 ENVIRONMENT
1.9.1 Environmental Statement
See Section 1.6.4.
1.9.3 GBHE Objectives
The Project will be carried out in accordance with SSHE Objectives.
1.9.4 Environmental Impact
No additional comments.
1.9.5 Environmental Criteria
No additional comments.
1.10 TRANSPORT AND SITING
1.10.1 Transport Stages
1.10.3 Existing Plant
1.10.4 Other Considerations

1.11 EXTERNAL AUTHORITIES
Change of plant or site status?
Plant or site inventories updated?
Chemicals controlled by international protocol?
Which authorities need to be contacted and who will be responsible?
1.12 DESIGN GUIDELINES AND CODES
Standard GBHE guidelines will be followed.
1.13 ORGANIZATION
(a) Suitability and availability of staff :
(b) New systems of work or procedures:
(c) Key operational and manning concepts:
(d) Construction manning:
1.14 EMERGENCY FACILITIES
1.15 FURTHER STUDIES
(a) Construction/demolition hazards (HAZCON)
(b) Area classification
(c) Fire prevention and protection
(d) Paving and drainage
(e) Cable routing
(f) Relief and blowdown

(g) Lifting equipment
(h) Noise
(j) Trip and alarms
(k) Layout
(l) Computer systems
(m) Control and operability
(n) Non-process hazards
(p) Equipment and pipework registration
(q) Critical machines
(r) Business risk
(s) Fire water run-off
(t) Building risk assessment (Process SHE Guide)
(u) Means of isolation
(v) Materials review
(w) Ergonomics
1.16 CONCLUSION
Responsibility and date for progressing actions?

HAZARD STUDY 1: REPORTING

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HAZARD STUDY 1: REPORTING