Application of Risk Analysis in Pilot Plants and Research Labs

Application of Risk Analysis

in Pilot Plants and Research Labs

 

Abstract

When an accident occurs in a Pilot Plant or Research Laboratory, involving loss of containment, chemical exposure, explosion or fire, people are often seriously and sometimes fatally injured. The subsequent investigation findings often identify the lack of a risk analysis as a root cause factor, before the work was started.

The approach towards the safety of pilot plant and research labs cannot be different from that of the full scale plant. However the uniqueness of challenge is associated with the understanding of the hazards in pilot plants and research labs. Investigations of laboratory-scale incidents reveals that the underlying causes are similar to those found in major chemical plant industries.

The combination of hazard identification and risk analysis is an organized effort to pinpoint weaknesses in the design and operation of facilities that could lead to accidental or unintentional chemical releases, fires or explosions. The studies assist organizations with the goal of improving safety and managing the risk of operations. Investigation findings of accidents in pilot plants and research labs often point to the absence of a risk analysis of the operation that led to the accident.

This presentation discusses the relationship between hazards and consequences of an upset event, the likelihood of the upset happening and the resulting risk to personnel, property and the environment. Some well-established risk procedures have been adapted to the task of hazard identification and risk assessment in the pilot plants and research labs.

The hazard identification process may be accomplished from readily available physical and chemical properties and the health effects of the chemicals to be used in the process. If formal hazard analysis is indicated then more detailed risk analysis techniques, such as Check-List, What-if or HAZOP are available. The choice is driven by the complexity of the planned synthesis and the nature and extent of consequences of an upset. These reviews should be led by an appropriately trained and experienced facilitator.

A powerful advantage of this approach is that it encourages and enables a research laboratory group to consider less obvious ways in which an upset may occur, even though it may seem unlikely at first consideration.