PROCESS HAZARD ANALYS

SEVERITY
Potential Effect(s) of
Process Step # Process Potential Hazard / Failure Mode
Failure

5
Over Pressure to associated
1 Loss of containment
Piping
5

Equipment untight before

2 Loss of Containment
unloading 4

Loss of Containment/ 6
3 Poor Pump Maintenance
Equipment Failure
DING OPERATION

6
4 Hose Rupture Loss of Containment
6

8
5 Receiving Tank Overfill Loss of Containment
7

10

6
6 Slip, Trip and Fall Loss Of control
6

7
 BLENDIN
6

Overheating in Blending Kettles/ 8

7 Exposure of danerous gases due Loss of Control
to excessive heat
7

7
8 Manual Handling Loss of Containment

10

Loss of
9 ForkLift Operation
Containment/Control
7

8
CESS HAZARD ANALYSIS - HAZOP

OCCURRENCE

DETECTION
R
Potential Cause(s) of Hazard / Failure Current Process Controls P
N

Design and pressure not aligned with maximum Piping is designed higher than max working
1 3
working pressure of pump pressure of Pump

Relief valve set to max piping design presseure 1 NA 0

Relieve valve not at safe location to prevent splash

and revert flow back into process on low pressure 1 NA 0
side

Gasket Design not compatible with service 4 Compatible gasket are available for the service 4

Inadequate design of hose pipe and not well All hoses are avaialbe as per design and double
3 1
connected check by operator before start of unloading

Coupling are checked for any damage and

Coupling design not compatible with truck and
2 compatibility with the truck by operator and 1
working pressure
pressure is kept under observation
Covered in SOP for attendant offloading under
Unattendent offloading 2 1
supervision

Pump seals failure 6 4

Visual inspection is done daily or before and after

No daily visual inspection 3 3
of loading and unloading

Design and pressure of hose not aligned with the Staff training has been conducted for slection of
2 1
service hose
Hose not inspected and tested for pressure 2 0
Not checked visually for damage 2 operator checks for damages 1

Level measurent is cross check with physical Dip.

Unoperational High level alarm on receiving tank 4 There is limit switch control to cut off pump supply 3
incase of overfilled
ullage not checked in receiving tank 2 Dip is taken before offloading the bulk 3
Confirm unloading plan - double check : ullage in
Loading/offloading plan not confirmed 3 receiving tank and volume to unload match, line- 2
up ok
2 ways communicaion between unloading gantry
Lack of Communication 2 2
and receiving tank monitoring station
Not following and using pathways, staircase, Proper walkways, handrails and scaffold with
handrails, ladders, platforms and sacffold as per 2 ralling are available on site and TBT is conducted 2
procedure before non routine activites
Bad lighting 3 Lighting are installed as per requirement 2
Procedure not defined for work at height and not Procedure are in place for routine work at height
3 2
clearly explained each step activites
Improper house keeping 3 Housekeeping is part of work procedures 2

No use of anti slip shoes/foot ware 3 Anti slip foot ware are mandotary for the site 2

Caution sign are displayed for hazard that can not

Unidentified trip hazards that cannot be eleminated. 3 3
be eleminated
Oil spillage on Floor 3 2
Automated scada control available for
Unavailability of automatic temperature control 4 3
temperature control
High temperature sensor and Alarm without Only visual (Red/yellw/blue) background
4 3
operator action notification with operator action
Independent high high temperature sensor and
4 NA 4
alarm to cut energy supply

Manual handling is included in SOPs where the

Unaware staff handling heavy loads without proper
4 risk assessment identified such a risk. Training is 3
techniques and equipment
ensured for each activity identified as risk

Properly designed equipment for such activities

Unavailability of lifting/handling equipment for
3 and provision of the correct type of equipment for 2
heavy & awkward equipment and objects
the job at hand are available

Lifting / handling equipment is not maintained so as

Scheduled maintenance program are in place to
to ensure correct operation (e.g. lifting device for 3 2
ensure.
drums; chain lift etc.).
unIdentified activities requiring handling of heavy list of such activities and their risk assessment is
2 2
& awkward equipment and objects provided

Daily forklift truck integrity checks as per forklift

truck standard, including hydraulic systems.
Mechanical failure of forklift truck (forks, brakes…) 6 3
Adequate tyres in good condition for the working
surface
Non-slippery floor. Area free for access and
Inadequate working environment 4 2
manoeuvring

Slow speed approaching pallet for pick-up. Fork

tilt adequately for pick-up. Forks positioned at
improper manoeuvre of Forklift truck 4 2
right height for pick-up. Forklift truck position in
straight-line to pallet for pick-up

Pallets compliant with pallet standard and of good

Unstable pallet/pallet load 2 quality (dry, free of damage). all packs to be 3
wrapped/strapped on pallets before movement
 Reviewed by:
Approved By:

OCCURRENCE

DETECTION
RESIDUAL

RESIDUAL

RESIDUAL
SEVERITY
Responsibilit Actions
R
y & Target Taken and
Recommended Corrective Actions P
Completion Completion
N
Date Date

Technical inspection plan must be

0
in place

0
0

0
 0

Alarm must sound for higher

0
temperature
Auto cutoff of temprature control
0
should be in place

0
 PROCESS HAZARD ANALYSIS

SEVERITY
Potential Effect(s) of
Process Step # Process Potential Hazard / Failure Mode
Failure

6
1 Pack Overfill Loss of Containment

2 Slip, Trip and Fall Loss Of control 7

3 Hazardous Tools/Knives Loss of Control 6

ING OPERATION

4 Pinch Poiint Loss Of control 6

5
Over Pressure to associated
5 Loss of containment
Piping
5

6 Manual Handling Loss of Containment

 FILLING O
7
6 Manual Handling Loss of Containment

10

Loss of
7 ForkLift Operation
Containment/Control
7

6
8 Poor Pump Maintenance Loss of Containment

6
9 Hose Rupture Loss of Containment
6
ESS HAZARD ANALYSIS - HAZOP

OCCURRENCE

DETECTION
R
Potential Cause(s) of Hazard / Failure Current Process Controls P
N

weigh scale are well calibrated and

Wieght Scale malfunction 3 4
maintained

Weight is doucble checked by supervisor

Weight not calculated according to density 2 3
and operator as per blend sheet

Filling operation not started witout filling

Filling weight not confirmed 4 3
sheet
Emergency shutdown is available to
Control malfunction 1 3
prevent overfill

Bad lighting 2 Lighting are installed as per requirement 2

Improper house keeping 2 Housekeeping is part of work procedures 2

Anti slip foot ware are mandotary for the

No use of anti slip shoes/foot ware 4 2
site
Caution sign are displayed for hazard that
Unidentified trip hazards that cannot be eleminated. 3 3
can not be eleminated
Oil spillage on Floor 2 2
Tools and training to utilize them are
Not utilizing specifiied tools for the job 4 provided to operators/ IBCs opener and 2
Drum bung seal openers
Procedure not followed for using knives and cutters/
4 PPEs to be worn while using sharp objects 2
sharp objects

Pinch points are well explained to operators

Not using proper body position 4 and body postions are explained to 3
specified operators

Tools are provided and respected

Not using proper tool for the Job 4 2
supervisor is responsible for safe usage

Equipment desgned considering pinch

Equipment not designed to eleminate pinch points 3 4
points elemination

Design and pressure not aligned with maximum Piping is designed higher than max working
1 3
working pressure of pump pressure of Pump

Relief valve set to max piping design presseure 1 NA 0

Relieve valve not at safe location to prevent splash

and revert flow back into process on low pressure 1 NA 0
side
Compatible gasket are available for the
Gasket Design not compatible with service 4 4
service
Manual handling is included in SOPs where
Unaware staff handling heavy loads without proper the risk assessment identified such a risk.
4 3
techniques and equipment Training is ensured for each activity
identified as risk
 Properly designed equipment for such
Unavailability of lifting/handling equipment for
3 activities and provision of the correct type of 2
heavy & awkward equipment and objects
equipment for the job at hand are available

Lifting / handling equipment is not maintained so as

Scheduled maintenance program are in
to ensure correct operation (e.g. lifting device for 3 2
place to ensure.
drums; chain lift etc.).
unIdentified activities requiring handling of heavy list of such activities and their risk
2 2
& awkward equipment and objects assessment is provided

Daily forklift truck integrity checks as per

forklift truck standard, including hydraulic
Mechanical failure of forklift truck (forks, brakes…) 6 3
systems. Adequate tyres in good condition
for the working surface

Non-slippery floor. Area free for access and

Inadequate working environment 4 2
manoeuvring

Slow speed approaching pallet for pick-up.

Fork tilt adequately for pick-up. Forks
improper manoeuvre of Forklift truck 4 positioned at right height for pick-up. Forklift 2
truck position in straight-line to pallet for
pick-up

Pallets compliant with pallet standard and

of good quality (dry, free of damage). all
Unstable pallet/pallet load 2 3
packs to be wrapped/strapped on pallets
before movement

Pump seals failure 6 4

Visual inspection is done daily or before

No daily visual inspection 3 3
and after of loading and unloading

Design and pressure of hose not aligned with the Staff training has been conducted for
2 1
service slection of hose
Hose not inspected and tested for pressure 2 0
Not checked visually for damage 2 operator checks for damages 1
 Reviewed by:
Approved By:

OCCURRENCE

DETECTION
RESIDUAL

RESIDUAL

RESIDUAL
SEVERITY
Responsibilit Actions
R
y & Target Taken and
Recommended Corrective Actions P
Completion Completion
N
Date Date

0
 0

Technical inspection plan must be

0
in place

0
0
 PROCESS HAZARD

Process Step # Process Potential Hazard / Failure Mode

1 Equipment untight before loading

OADING OPERATION
2 Over Pressure to associated Piping

3 Poor Pump Maintenance

4 Hose Rupture

5 Bulk Truck Movement

6 Receiving Loading Truck Overfill

7 Unexpected Pressure
 BULK LOA
7 Unexpected Pressure

8 Slip, Trip and Fall

 PROCESS HAZARD ANALYSIS - HAZOP

OCCURRENCE
SEVERITY
Potential Cause(s) of Hazard /
Potential Effect(s) of Failure
Failure

Inadequate design of hose pipe

4 2
and not well connected

Loss of Containment Coupling design not compatible

4 3
with truck and working pressure

6 Unattendent offloading 3
Design and pressure not aligned
7 with maximum working pressure of 2
pump
Relief valve set to max piping
5 3
design presseure
Loss of containment Relieve valve not at safe location
to prevent splash and revert flow
5 3
back into process on low pressure
side

Gasket Design not compatible with

6 3
service

6 Pump seals failure 2

6 No daily visual inspection 3

Loss of Containment
3
3
Design and pressure of hose not
7 2
aligned with the service
Hose not inspected and tested for
6 2
Loss of Containment pressure

6 Not checked visually for damage 3

3
Truck movement not locked with
7 2
chokes
Signal to prevent driving (Stop
7 3
Loss of Containment sign) not visiblle from cabin

6 Un attendent Loading 2
Chamber not checked before start
8 3
of Loading
Loss of Containment
8 Loading plan not confirmed 3

7 Lack of Communication 3

Site procedure not defining how to

6 monitor pressure before opening 2
up piping and containment

Loss of Control
 Site procedure not defining how to
Loss of Control open blown down valve piping and
7 3
containment to reduce pressure
before opening

3
3

Not following and using pathways,

staircase, handrails, ladders,
10 2
platforms and sacffold as per
procedure

7 Bad lighting 3
Improper/no use of harness belt at
8 3
height
Harness not inspected and
8 3
maintained for fit for use.

User did not conduct self check

Loss Of control 7 3
before using harness belt

Procedure not defined for work at

6 height and not clearly explained 3
each step
6 Improper house keeping 3

7 No use of anti slip shoes/foot ware 3

Unidentified trip hazards that

7 3
cannot be eleminated.
6 Oil spillage on Floor 3
OP

DETECTION
R
Current Process Controls P Recommended Corrective Actions
N

All hoses are avaialbe as per design and double check by operator
1
before start of unloading

Coupling are checked for any damage and compatibility with the
1
truck by operator and pressure is kept under observation

Covered in SOP for attendant offloading under supervision 1

Piping is designed higher than max working pressure of Pump 3

NA 0

NA 0

Compatible gasket are available for the service 4

Technical inspection plan must be in

4
place
Visual inspection is done daily or before and after of loading and
3
unloading

Staff training has been conducted for slection of hose 1

operator checks for damages 1

Procedure in place to always place choke before starting bulk

1
Loading and unloading

1 A sinage must be made for this

Un attended loading is not allowed 3

Always checked from top of chamber 2

Confirm unloading plan - double check : ullage in receiving tank and

2
volume to unload match, line-up ok (Covered in SOP)

2 ways communicaion between loading gantry and receiving end 2

Personnel are trained to monitor pressure guauges and procedure is

2
in place
 1

Proper walkways, handrails and scaffold with ralling are available on

2
site and TBT is conducted before non routine activites

Lighting are installed as per requirement 2

Training has been given to the personnel using harness belt 1

Periodic inspection is done for fit to use harness 1

Part of procedure to self check the harness belt condition before use 1

Procedure are in place for routine work at height activites 3

Housekeeping is part of work procedures 3

Anti slip foot ware are mandotary for the site 2

Caution sign are displayed for hazard that can not be eleminated 4

4
Reviewed by:
Approved By:

OCCURRENCE

DETECTION
RESIDUAL

RESIDUAL

RESIDUAL
SEVERITY
Responsibility & R
Actions Taken and
Target Completion P
Completion Date
Date N

0
0

0
 PROCESS HAZARD

Process Step # Process Potential Hazard / Failure Mode

1 Equipment untight before unloading

FLOADING OPERATION
2 Over Pressure to associated Piping

3 Poor Pump Maintenance

4 Hose Rupture

5 Bulk Truck Movement

5 Receiving Tank Overfill

5 Unexpected Pressure
 BULK OFFLO
5 Unexpected Pressure

5 Slip, Trip and Fall

 PROCESS HAZARD ANALYSIS - HAZOP

OCCURRENCE
SEVERITY
Potential Cause(s) of Hazard /
Potential Effect(s) of Failure
Failure

Inadequate design of hose pipe

4 2
and not well connected

Loss of Containment Coupling design not compatible

4 3
with truck and working pressure

6 Unattendent offloading 3
Design and pressure not aligned
7 with maximum working pressure of 2
pump
Relief valve set to max piping
5 3
design presseure
Loss of containment Relieve valve not at safe location
to prevent splash and revert flow
5 3
back into process on low pressure
side

Gasket Design not compatible with

6 3
service

6 Pump seals failure 2

6 No daily visual inspection 3

Loss of Containment
3
3
Design and pressure of hose not
7 2
aligned with the service
Hose not inspected and tested for
6 2
Loss of Containment pressure

6 Not checked visually for damage 3

3
Truck movement not locked with
7 2
chokes
Signal to prevent driving (Stop
7 3
Loss of Containment sign) not visiblle from cabin

Unoperational High level alarm on

8 2
receiving tank
ullage not checked in receiving
8 3
tank
Loss of Containment
Loading/offloading plan not
7 4
confirmed

7 Lack of Communication 2

Site procedure not defining how to

6 monitor pressure before opening 2
up piping and containment

Loss of Control
 Site procedure not defining how to
Loss of Control open blown down valve piping and
7 3
containment to reduce pressure
before opening

3
3

Not following and using pathways,

staircase, handrails, ladders,
10 2
platforms and sacffold as per
procedure

7 Bad lighting 3
Improper/no use of harness belt at
8 3
height
Harness not inspected and
8 3
maintained for fit for use.

User did not conduct self check

Loss Of control 7 3
before using harness belt

Procedure not defined for work at

6 height and not clearly explained 3
each step
6 Improper house keeping 3

7 No use of anti slip shoes/foot ware 3

Unidentified trip hazards that

7 3
cannot be eleminated.
6 Oil spillage on Floor 3
OP

DETECTION
R
Current Process Controls P Recommended Corrective Actions
N

All hoses are avaialbe as per design and double check by operator
1
before start of unloading

Coupling are checked for any damage and compatibility with the
1
truck by operator and pressure is kept under observation

Covered in SOP for attendant offloading under supervision 1

Piping is designed higher than max working pressure of Pump 3

NA 0

NA 0

Compatible gasket are available for the service 4

Technical inspection plan must be in

4
place
Visual inspection is done daily or before and after of loading and
3
unloading

Staff training has been conducted for slection of hose 1

operator checks for damages 1

Procedure in place to always place choke before starting bulk

1
Loading and unloading

1 A sinage must be made for this

Level measurent is cross check with physical Dip. There is limit

3
switch control to cut off pump supply incase of overfilled

Dip is taken before offloading the bulk 3

Confirm unloading plan - double check : ullage in receiving tank and

2
volume to unload match, line-up ok
2 ways communicaion between unloading gantry and receiving tank
2
monitoring station

Personnel are trained to monitor pressure guauges and procedure is

2
in place
 1

Proper walkways, handrails and scaffold with ralling are available on

2
site and TBT is conducted before non routine activites

Lighting are installed as per requirement 2

Training has been given to the personnel using harness belt 1

Periodic inspection is done for fit to use harness 1

Part of procedure to self check the harness belt condition before use 1

Procedure are in place for routine work at height activites 3

Housekeeping is part of work procedures 3

Anti slip foot ware are mandotary for the site 2

Caution sign are displayed for hazard that can not be eleminated 4

4
Reviewed by:
Approved By:

OCCURRENCE

DETECTION
RESIDUAL

RESIDUAL

RESIDUAL
SEVERITY
Responsibility & R
Actions Taken and
Target Completion P
Completion Date
Date N

0
0

0
 Severity, Occurrence, and Detection Criteria for Process HAZOP
SEVERITY EVALUATION CRITERIA SUGGESTED DETECTION EVALUATION CRITERIA
CRITERIA: Severity of Effect
DETECTION CRITERIA A B C SUGGESTED RANGE OF DETECTION METHODS RNK
EFFECT Customer Effect Manufacturing/Assembly Effect RNK
Very high severity ranking when a potential failure
Hazardous
mode effects safe operation and/or involves Or may endanger operator (machine or assembly) Almost Absolute certainty
without
noncompliance with government regulation without without warning.
10 Impossible of Non -Detection
L Cannot detect or is not checked. 10
warning
warning.
Very high severity ranking when a potential failure
Hazardous
mode effects safe operation and/or involves Or may endanger operator (machine or assembly) Very Controls will
with
noncompliance with government regulation with with warning.
9 Remote probably not detect.
L Control is achieved with indirect or random checks only. 9
warning
warning.
Or 100% of product may have to be scrapped, or
Controls have poor
Very High Part/item cannot be used (loss of primary function) part/item repaired in repair department with a repair 8 Remote
chance of detection.
L Control is achieved with visual inspection only. 8
time greater than one hour.
Or product may have to be sorted and a portion (less
Item usable but at a reduced level of performance. than 100%) scrapped or part/item repaired in repair Controls have poor
High
Customer very dissatisfied. department with a repair time between half an hour
7 Very Low
chance of detection.
L Control is achieved with double visual inspection only. 7
and an hour.
Or a portion (less than 100%) of the product may
Item usable but at a reduced level of performance. have to be scrapped with no sorting, or part /item Control is achieved with charting methods, such as SPC
Moderate
Customer dissatisfied. repaired in repair department with a repair time less 6 Low Controls may detect. K K (Statistical Process Control). 6
than half an hour.
Or 100% of product may have to be reworked, or Control is based on variable gauging after parts have left
Part/Item usable but at a reduced level of
Low
performance. Customer somewhat dissatisfied.
part/item repaired off-line but does not go to repair 5 Moderate Controls may detect. K the station, OR Go/No Go gauging performed on 100% of 5
department. the parts after parts have left the station.
Controls have a Error Detection in subsequent operations, OR gauging
Fit & Finish/ item does not conform. Defect noticed Or the product may have to be sorted with no scrap, Moderately
Very Low
by most customers (greater than 75%). and a portion (less than 100%) reworked. 4 High
good chance to K K performed on set-up and first-place check (for set-up 4
detect. Causes only).
Error Detection in -station, OR error Detection in
Or a portion (less than 100%) of the product may Controls have a
Fit & Finish does not conform. Defect noticed by subsequent operations by multiple layers of acceptance;
Minor
50% of customers.
have to be reworked with no scrap, on-line but outof- 3 High good chance to J K supply, select, install, verify. Cannot accept discrepant
3
station. detect.
part.
Or a portion (less than 100%) of the product may
Fit & Finish item does not conform. Defect noticed Controls almost Error Detection in -station (automatic gauging with
Very Minor
by discriminating customers (less than 25%).
have to be reworked with no scrap, on-line but 2 Very High
certain to detect.
J J automatic stop feature). Cannot pass discrepant part.
2
instation.
Or slight inconvenience to operation or operator, or Controls certain to Discrepant parts cannot be made because item has been
None No discernible effect.
no effect. 1 Very High
detect.
J error proofed by progress/product design. 1

This ranking results when a potential failure mode results in a final customer and/or a manufacturing/assembly A = Error Proofed NOTE: The ranking value of 1 is reserved for “Almost
Inspection
plant defect. The final customer should always be considered first. If both occur, use the higher of the two B = Gauging Certain.”
severities. Types:
C = Manual Inspection

SUGGESTED OCCURRENCE EVALUATION CRITERIA

Probability of Failure Likely Failure Rates RNK
Very High: Persistent failures ≥ 100 per thousand pieces 10
50 per thousand pieces 9
High: Frequent failures 20 per thousand pieces 8
10 per thousand pieces 7
Moderate: Occasional failures 5 per thousand pieces 6
2 per thousand pieces 5
Low: Relatively few failures 1 per thousand pieces 4
0.5 per thousand pieces 3
Remote: Failure is unlikely 0.1 per thousand pieces 2
≤ 0.01 per thousand pieces 1