Potential Hazardous Consequences

Scaffolding - Potential Hazardous Consequences

Property Damage (Scaffolding Collapse)

Common construction accidents involving scaffolding usually include either scaffold collapse and/or objects falling from the scaffold itself. Workers on the scaffold will normally utilize some type of equipment while on the scaffold, such as paint and related supplies, tools such as hammers, screw drivers or drills, as well as window cleaning equipment. Scaffold collapse may occur due to overload, as can be possible when heavy loads such as bricks, block, piping, pumps, or flanges are placed on a scaffold. In the case of a scaffold collapse, property damage to surrounding buildings and structures may occur.
Causes of scaffold construction accidents vary but may include:

o Unsecure scaffolding

o Poor or careless construction

o Use of poor quality of damaged material

o Missing or malfunctioning brakes

o Missing or malfunctioning fall safety systems

o Insufficient maintenance of scaffold

o Lack of or poorly conducted safety inspections

o Insufficient load rating / overloaded scaffold

o Dissimilar or incompatible components used

Severe weather conditions may also cause scaffold accidents. When safety precautions are not followed and workers utilize scaffolding in inclement weather, such as precipitation and/or high winds, unsafe conditions develop and include slippery surfaces and the possible “blowing off” of equipment.
Financial cost incurred in replacing the scaffold, lost time on the work being performed and repairing damage to facilities or equipment below or attached.

Personal Injury (Safety / Human Health)

Injury potential exists for workers on a scaffold in the event of a collapse or other malfunction. Injury may also occur when ascending or descending from a scaffold, passing materials to a scaffold, or inadequately guarded or protected openings. Contact with electrical equipment or power lines can also result in injury. In the case of a scaffold collapse, there is also potential for injury to people on the ground in the vicinity of the scaffold. People on the ground working or walking in the vicinity of the scaffold may be seriously injured by objects that fall from the scaffold.

Environmental Impact

In addition to the Property Damage and Personal Injury consequences stated above, facilities must also consider the potential environmental damage that could occur due to a scaffold malfunction.

Environmental damage due to releases to the air, soil, or bodies of water from equipment or supplies contained on the scaffold such as thinners, paint, toxic chemicals, etc.
In the event of a scaffold collapse, the potential for equipment damage that results in the release of toxic materials or other harmful substances to the environment (e.g. – scaffold collapses onto a process pipe resulting in a release).
Released material have the potential to cause personnel injuries as well as environmental damage.

Common construction accidents involving scaffolding usually include either scaffold collapse and/or objects falling from the scaffold itself. Workers on the scaffold will normally utilize some type of equipment while on the scaffold, such as paint and related supplies, tools such as hammers, screw drivers or drills, as well as window cleaning equipment. Scaffold collapse may occur due to overload, as can be possible when heavy loads such as bricks, block, piping, pumps, or flanges are placed on a scaffold. In the case of a scaffold collapse, property damage to surrounding buildings and structures may occur.
Causes of scaffold construction accidents vary but may include:

o Unsecure scaffolding

o Poor or careless construction

o Use of poor quality of damaged material

o Missing or malfunctioning brakes

o Missing or malfunctioning fall safety systems

o Insufficient maintenance of scaffold

o Lack of or poorly conducted safety inspections

o Insufficient load rating / overloaded scaffold

o Dissimilar or incompatible components used

Severe weather conditions may also cause scaffold accidents. When safety precautions are not followed and workers utilize scaffolding in inclement weather, such as precipitation and/or high winds, unsafe conditions develop and include slippery surfaces and the possible “blowing off” of equipment.
Financial cost incurred in replacing the scaffold, lost time on the work being performed and repairing damage to facilities or equipment below or attached.

Personal Injury (Safety / Human Health)

Environmental Impact

In addition to the Property Damage and Personal Injury consequences stated above, facilities must also consider the potential environmental damage that could occur due to a scaffold malfunction.

Environmental damage due to releases to the air, soil, or bodies of water from equipment or supplies contained on the scaffold such as thinners, paint, toxic chemicals, etc.
In the event of a scaffold collapse, the potential for equipment damage that results in the release of toxic materials or other harmful substances to the environment (e.g. – scaffold collapses onto a process pipe resulting in a release).
Released material have the potential to cause personnel injuries as well as environmental damage.

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Field Review of Permits - Potential Hazardous Consequences

Property Damage (Fire / Explosion) – Depending upon the activity being performed

An energy release that occurs after opening the wrong equipment due to improper inspection of work site, resulting in damage to the assets.
Fire and explosion due to ignitable material leakage from the equipment around job location.
Contamination of product tanks resulting in corrosion of tank, loss of product, and reprocessing costs.
Poor dispersion of ignitable material due to barricading of work area for carrying out construction activities leading to pool formation having potential for explosion.
Incorrect/inadequate support for process fluid pipeline during maintenance leading to release of hazardous material with potential of catastrophic failure.
Excavation damaging buried pipelines leading to release of ignitable material, vapor cloud explosion and resulting fire.

Personal Injury (Safety / Human Health) – Depending upon the activity being performed

Improper identification of presence of hazardous material resulting in personnel exposure to toxic materials resulting in injuries or fatalities
Failure to identify the requirement for special personnel protective equipment (PPE) for the job.
Failure to identify location-specific hazards and controls
Not identifying hazards present at workplace arising from inadequate design (e.g., limited escape route, poor access to the equipment under maintenance).
Not identifying hazards due to temporary modification/construction activities (e.g., protruding scaffolding pipes, threat of falling objects, poor illumination due to barricading).
Opening of standby equipment resulting in exposure to toxic chemicals leading to injury or fatality.
Line break into wrong pipeline containing toxic materials.
Use of contaminated hoses for draining, flushing, or purging.
Contamination of product tanks due to unloading of wrong material into tank, releasing toxic vapors

An energy release that occurs after opening the wrong equipment due to improper inspection of work site, resulting in damage to the assets.
Fire and explosion due to ignitable material leakage from the equipment around job location.
Contamination of product tanks resulting in corrosion of tank, loss of product, and reprocessing costs.
Poor dispersion of ignitable material due to barricading of work area for carrying out construction activities leading to pool formation having potential for explosion.
Incorrect/inadequate support for process fluid pipeline during maintenance leading to release of hazardous material with potential of catastrophic failure.
Excavation damaging buried pipelines leading to release of ignitable material, vapor cloud explosion and resulting fire.

Personal Injury (Safety / Human Health) – Depending upon the activity being performed

Improper identification of presence of hazardous material resulting in personnel exposure to toxic materials resulting in injuries or fatalities
Failure to identify the requirement for special personnel protective equipment (PPE) for the job.
Failure to identify location-specific hazards and controls
Not identifying hazards present at workplace arising from inadequate design (e.g., limited escape route, poor access to the equipment under maintenance).
Not identifying hazards due to temporary modification/construction activities (e.g., protruding scaffolding pipes, threat of falling objects, poor illumination due to barricading).
Opening of standby equipment resulting in exposure to toxic chemicals leading to injury or fatality.
Line break into wrong pipeline containing toxic materials.
Use of contaminated hoses for draining, flushing, or purging.
Contamination of product tanks due to unloading of wrong material into tank, releasing toxic vapors

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Equipment Identification - Potential Hazardous Consequences

Personal Injury (Safety / Human Health)

Improper tagging or identification of equipment or piping may lead to release of hazardous material resulting in personnel exposure to fire and explosion, radiation or toxic vapors.
- Personnel or off-site injuries due the release of flammable fluids, combustible vapors, or toxic materials.
- Personal or off-site injuries due to fire or explosion resulting from a release.

Property Damage (Fire / Explosion)

A release and subsequent fire of hazardous material resulting from opening the wrong fitting or equipment due to improper tagging of equipment.
Connections resulting in release of hazardous material release due to
- Incompatible materials mixing and reacting resulting in a release of energy
- Material being fed into equipment made of incompatible Material of Construction

Chemical Release / Environmental Impact (On-Site)

In addition to the Property Damage and Personal Injury consequences stated above, facilities should also consider the potential for escalation that could result in environmental damage or additional personal injuries occurring on-site.

Environmental damage due to releases to the air, soil, or bodies of water resulting from opening the wrong fitting or equipment.

Chemical Release / Environmental Impact (Off-Site)

Environmental damage due to releases to the air, soil, or bodies of water resulting from opening the wrong fitting or equipment.

Line Opening - Potential Hazardous Consequences

Property Damage (Fire / Explosion)

A release of hazardous material during a line or equipment opening can cause property damage if released materials are flammable. Depending on the surrounding area, the released material may find an ignition source and cause a fire or an explosion.

Personal Injury (Safety / Human Health)

Line or Equipment Opening, if not done properly, can lead to release of hazardous materials and personnel exposure with serious injuries or fatalities
Exposure to corrosive materials (i.e. acids or caustic) causing chemical burns
- Exposure to corrosive materials (i.e. acids or caustic) causing chemical burns
- Exposure to toxic materials (i.e. benzene, hydrogen sulfide, phenol)
- Exposure to hot materials (i.e. steam) causing thermal burns
- Release of material under pressure causing an injury
If these materials are flammable the release may find an ignition source leading to a fire or an explosion.

Chemical Release / Environmental Impact (On-Site)

In addition to the Property Damage and Personal Injury consequences stated above, facilities must also consider the potential for escalation that could result in environmental damage or additional personal injuries occurring on-site.

Environmental damage due to releases to the air, soil, or bodies of water resulting from line or equipment opening hazardous material releases
Personnel injuries outside of the immediate area due the release of toxic materials from line or equipment opening activities
Personal injuries outside of the immediate area due to fire or explosions resulting from possible ignition of flammable materials released during line or equipment opening.

Chemical Release / Environmental Impact (Off-Site)

Environmental damage due to releases to the air, soil, or bodies of water resulting from line or equipment opening hazardous material releases
Personnel injuries outside of the plant boundaries due the release of toxic materials from line or equipment opening activities
Personal injuries outside of the plant boundaries due to fire or explosions resulting from possible ignition of flammable materials released during line or equipment opening.

A release of hazardous material during a line or equipment opening can cause property damage if released materials are flammable. Depending on the surrounding area, the released material may find an ignition source and cause a fire or an explosion.

Personal Injury (Safety / Human Health)

Line or Equipment Opening, if not done properly, can lead to release of hazardous materials and personnel exposure with serious injuries or fatalities
Exposure to corrosive materials (i.e. acids or caustic) causing chemical burns
- Exposure to corrosive materials (i.e. acids or caustic) causing chemical burns
- Exposure to toxic materials (i.e. benzene, hydrogen sulfide, phenol)
- Exposure to hot materials (i.e. steam) causing thermal burns
- Release of material under pressure causing an injury
If these materials are flammable the release may find an ignition source leading to a fire or an explosion.

Chemical Release / Environmental Impact (On-Site)

Environmental damage due to releases to the air, soil, or bodies of water resulting from line or equipment opening hazardous material releases
Personnel injuries outside of the immediate area due the release of toxic materials from line or equipment opening activities
Personal injuries outside of the immediate area due to fire or explosions resulting from possible ignition of flammable materials released during line or equipment opening.

Chemical Release / Environmental Impact (Off-Site)

Environmental damage due to releases to the air, soil, or bodies of water resulting from line or equipment opening hazardous material releases
Personnel injuries outside of the plant boundaries due the release of toxic materials from line or equipment opening activities
Personal injuries outside of the plant boundaries due to fire or explosions resulting from possible ignition of flammable materials released during line or equipment opening.

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Hot Tapping - Potential Hazardous Consequences

Potential Hazardous Consequences

Personal Injury (Safety / Human Health)

Hot work presents direct personnel hazards to those involved in the task, or to those working nearby.
- Skin/eye burns, and electric shock are potential direct hazards.  A hot surface or a spark can burn skin, either by contact or from radiated heat. The eyes are particularly sensitive to burning, including from light radiation - “arc eye”.
- Potential of personnel overexposure to welding or flame cutting fumes, especially:
  - If ventilation is inadequate.
  - Inappropriate or insufficient PPE.
- Injuries from sparks, etc., to personnel working in the area or passing nearby (or at a lower level below the work) may occur if the area is not properly isolated or access is not restricted and there is no additional protection such as a fire blanket.
  - While the direct hazards of hot work are important, the risks from fires and explosions are typically more significant, especially in operational areas.

Property Damage (Fire / Explosion)

Creating an ignition source (flame, heat, sparks, non-intrinsically safe equipment, molten metal, or direct flames) in a combustible atmosphere (flammable materials/vapors) leading to fire or explosion.
- Caution must be taken when working near openings or cracks in walls, flooring, open doorways, and windows.
Impinging heat to surrounding process equipment, causing possible thermal expansion resulting in the release of hydrocarbons,
Arc from welding, possibly setting off fire detection / mitigation systems (i.e., deluge systems, alarms resulting in possible unit shutdowns, etc.)
Interference with other simultaneous work in close proximity (e.g., work involving breaking containment and potential release of combustible gases while hot work is present.)
Hazards associated with hot tap equipment:
- Damage and defective parts, if not replaced prior to start of the job
- Improper grounding
- Oxy-fuel equipment
  - If oxy-acetylene cylinders do not have sufficient material in the cylinders prior to start of the job, backflow can happen if one cylinder goes empty during operation which can cause:
    - A system pressure imbalance.
    - Mixing of oxygen and fuel inside the hose.
  - Flashback caused by reverse flow of gas through the torch and back through to the hose, regulator and/or cylinder, potentially causing an explosion
Fire or explosion caused by ignition of flammable/combustible vapors/materials present in processing equipment such as tanks, vessels, and piping, etc., that have void spaces or liners (i.e., double-walled tanks and piping, double-bottom tanks)

Chemical Release / Environmental Impact (On-Site and Off-Site)

In addition to the Personal Injury and Property Damage consequences stated above, facilities must also consider the potential for escalation that could result in environmental damage or additional personal injuries occurring on-site.

Environmental damage due to releases to the air, soil, or bodies of water resulting from hot work-related fires, explosions, equipment damage, etc.
Injuries to on-site personnel not directly involved in the hot tap operation, or to emergency responders or members of the public (off-site) due the release of flammable, combustible vapors, or toxic materials due to products of combustion resulting from hot work-related fires.
Personal injuries due to fire escalation or explosions resulting from hot work-related fires.

Personal Injury (Safety / Human Health)

Hot work presents direct personnel hazards to those involved in the task, or to those working nearby.
- Skin/eye burns, and electric shock are potential direct hazards.  A hot surface or a spark can burn skin, either by contact or from radiated heat. The eyes are particularly sensitive to burning, including from light radiation - “arc eye”.
- Potential of personnel overexposure to welding or flame cutting fumes, especially:
  - If ventilation is inadequate.
  - Inappropriate or insufficient PPE.
- Injuries from sparks, etc., to personnel working in the area or passing nearby (or at a lower level below the work) may occur if the area is not properly isolated or access is not restricted and there is no additional protection such as a fire blanket.
  - While the direct hazards of hot work are important, the risks from fires and explosions are typically more significant, especially in operational areas.

Property Damage (Fire / Explosion)

Creating an ignition source (flame, heat, sparks, non-intrinsically safe equipment, molten metal, or direct flames) in a combustible atmosphere (flammable materials/vapors) leading to fire or explosion.
- Caution must be taken when working near openings or cracks in walls, flooring, open doorways, and windows.
Impinging heat to surrounding process equipment, causing possible thermal expansion resulting in the release of hydrocarbons,
Arc from welding, possibly setting off fire detection / mitigation systems (i.e., deluge systems, alarms resulting in possible unit shutdowns, etc.)
Interference with other simultaneous work in close proximity (e.g., work involving breaking containment and potential release of combustible gases while hot work is present.)
Hazards associated with hot tap equipment:
- Damage and defective parts, if not replaced prior to start of the job
- Improper grounding
- Oxy-fuel equipment
  - If oxy-acetylene cylinders do not have sufficient material in the cylinders prior to start of the job, backflow can happen if one cylinder goes empty during operation which can cause:
    - A system pressure imbalance.
    - Mixing of oxygen and fuel inside the hose.
  - Flashback caused by reverse flow of gas through the torch and back through to the hose, regulator and/or cylinder, potentially causing an explosion
Fire or explosion caused by ignition of flammable/combustible vapors/materials present in processing equipment such as tanks, vessels, and piping, etc., that have void spaces or liners (i.e., double-walled tanks and piping, double-bottom tanks)

Chemical Release / Environmental Impact (On-Site and Off-Site)

Environmental damage due to releases to the air, soil, or bodies of water resulting from hot work-related fires, explosions, equipment damage, etc.
Injuries to on-site personnel not directly involved in the hot tap operation, or to emergency responders or members of the public (off-site) due the release of flammable, combustible vapors, or toxic materials due to products of combustion resulting from hot work-related fires.
Personal injuries due to fire escalation or explosions resulting from hot work-related fires.

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Energy Isolation - Potential Hazardous Consequences

Property Damage (Fire / Explosion)

A release of hazardous material during a task requiring Lock-Out/Tag-Out can cause property damage if released materials are flammable, combustible, corrosive, or toxic. Depending on the surrounding area, the released material may find an ignition source and cause a fire or an explosion. It could also damage other equipment or require specialized cleaning and removal. A release can happen if the equipment being worked on is not isolated properly and chemical energy is released unexpectedly.

Personal Injury (Safety / Human Health)

Lock-Out/Tag-Out if not done properly, can lead to release of hazardous materials (chemical and thermal energy) and personnel exposure with serious injuries or fatalities
- Exposure to corrosive materials (i.e., acids or caustic) causing chemical burns
- Exposure to toxic materials (i.e., benzene, hydrogen sulfide, phenol)
- Exposure to hot materials (i.e., steam) causing thermal burns
- Release of material under pressure
- Exposure to oxygen-deficient or asphyxiating atmospheres
- Release of flammable materials

Personnel can also sustain serious injury or fatality due to being struck or caught by moving equipment or being caught in moving equipment that is not properly de-energized. Examples include:
- Serious injury or fatality may result from being caught in rotating equipment or from working on improperly de-energized electrical equipment.

Chemical Release / Environmental Impact (On-Site)

In addition to the Property Damage and Personal Injury consequences stated above, facilities must also consider the potential for escalation that could result in on-site environmental damage.

Environmental damage due to releases to the air, soil, or bodies of water resulting from work activities where lines or equipment were not properly isolated (locked-out/tagged-out).

Chemical Release / Environmental Impact (Off-Site)

Environmental damage due to releases to the air, soil, or bodies of water resulting from work activities where lines or equipment were not properly isolated (locked-out/tagged-out).

A release of hazardous material during a task requiring Lock-Out/Tag-Out can cause property damage if released materials are flammable, combustible, corrosive, or toxic. Depending on the surrounding area, the released material may find an ignition source and cause a fire or an explosion. It could also damage other equipment or require specialized cleaning and removal. A release can happen if the equipment being worked on is not isolated properly and chemical energy is released unexpectedly.

Personal Injury (Safety / Human Health)

Lock-Out/Tag-Out if not done properly, can lead to release of hazardous materials (chemical and thermal energy) and personnel exposure with serious injuries or fatalities
- Exposure to corrosive materials (i.e., acids or caustic) causing chemical burns
- Exposure to toxic materials (i.e., benzene, hydrogen sulfide, phenol)
- Exposure to hot materials (i.e., steam) causing thermal burns
- Release of material under pressure
- Exposure to oxygen-deficient or asphyxiating atmospheres
- Release of flammable materials

Personnel can also sustain serious injury or fatality due to being struck or caught by moving equipment or being caught in moving equipment that is not properly de-energized. Examples include:
- Serious injury or fatality may result from being caught in rotating equipment or from working on improperly de-energized electrical equipment.

Chemical Release / Environmental Impact (On-Site)

In addition to the Property Damage and Personal Injury consequences stated above, facilities must also consider the potential for escalation that could result in on-site environmental damage.

Environmental damage due to releases to the air, soil, or bodies of water resulting from work activities where lines or equipment were not properly isolated (locked-out/tagged-out).

Chemical Release / Environmental Impact (Off-Site)

Environmental damage due to releases to the air, soil, or bodies of water resulting from work activities where lines or equipment were not properly isolated (locked-out/tagged-out).

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Excavation - Potential Hazardous Consequences

Property Damage (Fire / Explosion) – While performing Hot Work in an Excavation

Creating an ignition source (flame, heat, sparks, non-intrinsically safe equipment, molten metal or direct flames) in a combustible atmosphere (flammable materials/vapors) leading to fire or explosion.
Impinging heat to surrounding process equipment, causing possible thermal expansion resulting in the release of hydrocarbons,
Arc from welding, possibly setting off fire detection / mitigation systems (i.e., deluge systems, alarms resulting in possible unit shut downs, etc.)
Interference with other simultaneous work in close proximity (e.g., work involving breaking containment and potential release of combustible gases while hot work is present.)
Hazards associated with welding equipment:
- Damage and defective parts, if not replaced prior to start of the job
- Improper grounding
- Oxy-fuel equipment
  - If oxy-acetylene cylinders do not have sufficient material in the cylinders prior to start of the job, backflow can happen if one cylinder goes empty during operation which can cause:
    - A system pressure imbalance.
    - Mixing of oxy and fuel inside the hose.
  - Flashback caused by reverse flow of gas through the torch and back through to the hose, regulator and/or cylinder, potentially causing an explosion
Fire or explosion caused by ignition of flammable/combustible vapors/materials present in the excavation.

Personal Injury (Safety / Human Health)

Excavation cave-ins leading to entrapment and potential suffocation.
Falling into excavations leading to injury of death.

Equipment Filling and Mixing - Potential Hazardous Consequences

Property Damage (Fire / Explosion)

Contact of incompatible chemicals may lead to uncontrolled reactions, leading to rupture of the vessel or piping system resulting in fire and explosions.
Damage to assets
Damage to buildings/houses in nearby community

Personal Injury (Safety / Human Health)

Fatal injury due to exposure to toxic fumes from mixing of wrong chemicals
Fatal injury due to explosion from reaction of wrong chemicals
Nausea and lightheadedness due to inhalation of fumes
Vomiting, headache and high blood pressure

Chemical Release / Environmental Impact (On-Site)

Evacuation of onsite population to outside of facility
Evacuation of personnel into Safe havens
Declaration of Site Level Emergency

Chemical Release / Environmental Impact (Off-Site)

Extensive air pollution
Breathing difficulties in general public
Shelter-in-place in nearby community

Temporary Instrumentation and Controls Bypass - Potential Hazardous Consequences

Each instrumented safeguard exists for a reason, protecting against some hazard to personnel, the environment, or to assets. The potential consequence of improper bypassing or jumpering of safeguards is the occurrence of the very hazard the safeguard was there to prevent or miti-gate. These hazards typically include fires, explosions, catastrophic overpressure events, toxic releases, or exposure to personnel to hazards inherent to the process equipment.

Some things to consider:

Most instruments and controls were installed for a reason, are you able to confirm the reason for the device that you are considering to bypass?
What does your process safety information (PSI) say? Have you referred to interlock specification sheet, Process Hazard Assessment (PHA), etc. to verify the purpose for the device that you are considering to bypass?
Don’t forget, bypassing a device is a change to your process safety information PSI. Therefore, have you captured the bypass in your MOC program like you would any other process change?
Recognize that many devices may be identified in your PHA as a safeguard to manage/mitigate risk. Therefore, bypassing is such a device is essentially elevating risk. Are you authorized to bypass the device and increase risk?
Does your authorization process define a specific communication/approval protocol required/developed to ensure safe review, design/implementation of interim measures, etc.?
There may not be a direct pathway from the bypassing of a device to an incident. In some instances, even if it is bypassed, you may not even see an event. How are you preventing normalization of deviation associated with this phenomenon (i.e., it hasn’t happened before)?
Be aware that such bypassing without consequences could lead to a false sense of security with operating and maintenance personnel (i.e., it hasn’t happened before)?

Property Damage (Fire / Explosion)

A release of hazardous material resulting from bypassing or jumpering an instrument or control device can cause property damage if released materials are flammable. Depending on the surrounding area, the released material may find an ignition source and cause a fire or an explosion.

Personal Injury (Safety/Human Health)

Bypassing or jumpering an instrument or control device, if not done properly, can lead to release of hazardous materials and personnel exposure with serious injuries or fatalities
- Exposure to corrosive materials (i.e. acids or caustic) causing chemical burns
- Exposure to toxic materials (i.e. benzene, hydrogen sulfide, phenol)
- Exposure to hot materials (i.e. steam) causing thermal burns
- Release of material under pressure causing an injury

If these materials are flammable the release may find an ignition source leading to a fire or an explosion.

Chemical Release/Environmental Release (On-Site)

In addition to the Property Damage and Personal Injury consequences stated above, facilities must also consider the potential for escaltion that could result in environmental damamge or additional personal injuries occurring on-site.

Environmental damage due to releases to the air, soil, or bodies of water resulting from line or equipment opening hazardous material releases
Personnel injuries outside of the immediate area due the release of toxic materials from line or equipment opening activities
Personal injuries outside of the immediate area due to fire or explosions resulting from possible ignition of flammable materials released during line or equipment opening.

Chemical Release/Environmental Release (Off-Site)

Environmental damage due to releases to the air, soil, or bodies of water resulting from line or equipment opening hazardous material releases
Personnel injuries outside of the plant boundaries due the release of toxic materials from line or equipment opening activities

Some things to consider:

Most instruments and controls were installed for a reason, are you able to confirm the reason for the device that you are considering to bypass?
What does your process safety information (PSI) say? Have you referred to interlock specification sheet, Process Hazard Assessment (PHA), etc. to verify the purpose for the device that you are considering to bypass?
Don’t forget, bypassing a device is a change to your process safety information PSI. Therefore, have you captured the bypass in your MOC program like you would any other process change?
Recognize that many devices may be identified in your PHA as a safeguard to manage/mitigate risk. Therefore, bypassing is such a device is essentially elevating risk. Are you authorized to bypass the device and increase risk?
Does your authorization process define a specific communication/approval protocol required/developed to ensure safe review, design/implementation of interim measures, etc.?
There may not be a direct pathway from the bypassing of a device to an incident. In some instances, even if it is bypassed, you may not even see an event. How are you preventing normalization of deviation associated with this phenomenon (i.e., it hasn’t happened before)?
Be aware that such bypassing without consequences could lead to a false sense of security with operating and maintenance personnel (i.e., it hasn’t happened before)?

Property Damage (Fire / Explosion)

A release of hazardous material resulting from bypassing or jumpering an instrument or control device can cause property damage if released materials are flammable. Depending on the surrounding area, the released material may find an ignition source and cause a fire or an explosion.

Personal Injury (Safety/Human Health)

Bypassing or jumpering an instrument or control device, if not done properly, can lead to release of hazardous materials and personnel exposure with serious injuries or fatalities
- Exposure to corrosive materials (i.e. acids or caustic) causing chemical burns
- Exposure to toxic materials (i.e. benzene, hydrogen sulfide, phenol)
- Exposure to hot materials (i.e. steam) causing thermal burns
- Release of material under pressure causing an injury

If these materials are flammable the release may find an ignition source leading to a fire or an explosion.

Chemical Release/Environmental Release (On-Site)

Environmental damage due to releases to the air, soil, or bodies of water resulting from line or equipment opening hazardous material releases
Personnel injuries outside of the immediate area due the release of toxic materials from line or equipment opening activities
Personal injuries outside of the immediate area due to fire or explosions resulting from possible ignition of flammable materials released during line or equipment opening.

Chemical Release/Environmental Release (Off-Site)

Environmental damage due to releases to the air, soil, or bodies of water resulting from line or equipment opening hazardous material releases
Personnel injuries outside of the plant boundaries due the release of toxic materials from line or equipment opening activities

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Confined Space Entry - Potential Hazardous Consequences

Potential Hazardous Consequences

Property Damage (Fire / Explosion)

A release of hazardous material during a confined space entry can be caused by improper cleaning of scale in the equipment and hazardous material being trapped or improperly isolated equipment. Property damage can happen if released materials are flammable and ignition sources are available during the confined space entry.

Personal Injury (Safety / Human Health)

Confined Space Entry, if not done properly, can lead to release of hazardous materials and personnel exposure with serious injuries or fatalities
- Exposure to corrosive materials (i.e. acids or caustic) causing chemical burns
- Exposure to toxic materials (i.e. benzene, hydrogen sulfide, phenol)
- Exposure to hot materials (i.e. steam) causing thermal burns
- Release of material under pressure causing an injury
- Exposure to oxygen deficient atmosphere
- Engulfment by solids during confined space entry into pits etc.
- Exposure to radiation from instrumentation (i.e. level transmitters)
- Fall injuries inside confined space
If these materials are flammable, the release may find an ignition source leading to a fire or an explosion.

Chemical Release / Environmental Impact (On-Site)

Environmental damage due to releases of hazardous materials to the air, soil, or bodies of water resulting from improper isolation during confined space entry
Personnel injuries due the release of toxic materials resulting from improper isolation during confined space entry activities
Personal injuries due to fire or explosions resulting from possible ignition of flammable materials released from improper isolation during confined space entry

Chemical Release / Environmental Impact (Off-Site)

Environmental damage due to releases of hazardous materials to the air, soil, or bodies of water resulting from improper isolation during confined space entry
Personnel injuries due the release of toxic materials resulting from improper isolation during confined space entry activities
Personal injuries due to fire or explosions resulting from possible ignition of flammable materials released from improper isolation during confined space entry

Property Damage (Fire / Explosion)

A release of hazardous material during a confined space entry can be caused by improper cleaning of scale in the equipment and hazardous material being trapped or improperly isolated equipment. Property damage can happen if released materials are flammable and ignition sources are available during the confined space entry.

Personal Injury (Safety / Human Health)

Confined Space Entry, if not done properly, can lead to release of hazardous materials and personnel exposure with serious injuries or fatalities
- Exposure to corrosive materials (i.e. acids or caustic) causing chemical burns
- Exposure to toxic materials (i.e. benzene, hydrogen sulfide, phenol)
- Exposure to hot materials (i.e. steam) causing thermal burns
- Release of material under pressure causing an injury
- Exposure to oxygen deficient atmosphere
- Engulfment by solids during confined space entry into pits etc.
- Exposure to radiation from instrumentation (i.e. level transmitters)
- Fall injuries inside confined space
If these materials are flammable, the release may find an ignition source leading to a fire or an explosion.

Chemical Release / Environmental Impact (On-Site)

Environmental damage due to releases of hazardous materials to the air, soil, or bodies of water resulting from improper isolation during confined space entry
Personnel injuries due the release of toxic materials resulting from improper isolation during confined space entry activities
Personal injuries due to fire or explosions resulting from possible ignition of flammable materials released from improper isolation during confined space entry

Chemical Release / Environmental Impact (Off-Site)

Environmental damage due to releases of hazardous materials to the air, soil, or bodies of water resulting from improper isolation during confined space entry
Personnel injuries due the release of toxic materials resulting from improper isolation during confined space entry activities
Personal injuries due to fire or explosions resulting from possible ignition of flammable materials released from improper isolation during confined space entry

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Hot Work - Potential Hazardous Consequences

Property Damage (Fire / Explosion)

Creating an ignition source (flame, heat, sparks, non-intrinsically safe equipment, molten metal or direct flames) in a combustible atmosphere (flammable materials/vapors) leading to fire or explosion.
- Caution must be taken when working near openings or cracks in walls, flooring, open doorways and windows.
Impinging heat to surrounding process equipment, causing possible thermal expansion re-sulting in the release of hydrocarbons,
Arc from welding, possibly setting off fire detection / mitigation systems (i.e., deluge sys-tems, alarms resulting in possible unit shut downs, etc.)
Interference with other simultaneous work in close proximity (e.g., work involving breaking containment and potential release of combustible gases while hot work is present.)
Hazards associated with welding equipment:
- Damage and defective parts, if not replaced prior to start of the job
- Improper grounding
- Oxy-fuel equipment
  - If oxy-acetylene cylinders do not have sufficient material in the cylinders pri-or to start of the job, backflow can happen if one cylinder goes empty during operation which can cause:
    - A system pressure imbalance.
    - Mixing of oxy and fuel inside the hose.

Flashback caused by reverse flow of gas through the torch and back through to the hose, regulator and/or cylinder, potentially causing an explosion
Fire or explosion caused by ignition of flammable/combustible vapors/materials present in processing equipment such as tanks, vessels and piping, etc., that have void spaces or liners (i.e., double-walled tanks and piping, double-bottom tanks)

Personal Injury (Safety / Human Health)

Hot work presents direct personnel hazards to those involved in the task, or working nearby.

Skin/eye burns and electric shock are potential direct hazards. A hot surface or a spark can burn skin, either by contact or from radiated heat. The eyes are particular-ly sensitive to burning, including that from light radiation - “arc eye”.
Potential of personnel overexposure to welding or flame cutting fumes, especially:
- If ventilation is inadequate.
- Inappropriate or insufficient PPE.

Injuries from sparks, etc., to personnel working in the area or passing nearby (or at a lower level below the work) may occur if the area is not properly isolated or access is restricted and there is no additional protection such as a fire blanket.
- While the direct hazards of hot work are important, the risks from fires and explosions are typically more significant, especially in operational areas.

Chemical Release / Environmental Impact (On-Site)

Environmental damage due to releases to the air, soil, or bodies of water resulting from hot work related fires, explosions, equipment damage, etc.
Personnel injuries due the release of flammable, combustible vapors, or toxic materials due to products of combustion resulting from hot work related fires.
Personal injuries due to fire escalation or explosions resulting from hot work related fires.

Chemical Release / Environmental Impact (Off-Site)

Environmental damage due to releases to the air, soil, or bodies of water resulting from hot work related fires, explosions, equipment damage, etc.
Personnel injuries due the release of flammable, combustible vapors, or toxic materials due to products of combustion resulting from hot work related fires.
Personal injuries due to fire escalation or explosions resulting from hot work related fires.

Creating an ignition source (flame, heat, sparks, non-intrinsically safe equipment, molten metal or direct flames) in a combustible atmosphere (flammable materials/vapors) leading to fire or explosion.
- Caution must be taken when working near openings or cracks in walls, flooring, open doorways and windows.
Impinging heat to surrounding process equipment, causing possible thermal expansion re-sulting in the release of hydrocarbons,
Arc from welding, possibly setting off fire detection / mitigation systems (i.e., deluge sys-tems, alarms resulting in possible unit shut downs, etc.)
Interference with other simultaneous work in close proximity (e.g., work involving breaking containment and potential release of combustible gases while hot work is present.)
Hazards associated with welding equipment:
- Damage and defective parts, if not replaced prior to start of the job
- Improper grounding
- Oxy-fuel equipment
  - If oxy-acetylene cylinders do not have sufficient material in the cylinders pri-or to start of the job, backflow can happen if one cylinder goes empty during operation which can cause:
    - A system pressure imbalance.
    - Mixing of oxy and fuel inside the hose.

Flashback caused by reverse flow of gas through the torch and back through to the hose, regulator and/or cylinder, potentially causing an explosion
Fire or explosion caused by ignition of flammable/combustible vapors/materials present in processing equipment such as tanks, vessels and piping, etc., that have void spaces or liners (i.e., double-walled tanks and piping, double-bottom tanks)

Personal Injury (Safety / Human Health)

Hot work presents direct personnel hazards to those involved in the task, or working nearby.

Skin/eye burns and electric shock are potential direct hazards. A hot surface or a spark can burn skin, either by contact or from radiated heat. The eyes are particular-ly sensitive to burning, including that from light radiation - “arc eye”.
Potential of personnel overexposure to welding or flame cutting fumes, especially:
- If ventilation is inadequate.
- Inappropriate or insufficient PPE.

Injuries from sparks, etc., to personnel working in the area or passing nearby (or at a lower level below the work) may occur if the area is not properly isolated or access is restricted and there is no additional protection such as a fire blanket.
- While the direct hazards of hot work are important, the risks from fires and explosions are typically more significant, especially in operational areas.

Chemical Release / Environmental Impact (On-Site)

Environmental damage due to releases to the air, soil, or bodies of water resulting from hot work related fires, explosions, equipment damage, etc.
Personnel injuries due the release of flammable, combustible vapors, or toxic materials due to products of combustion resulting from hot work related fires.
Personal injuries due to fire escalation or explosions resulting from hot work related fires.

Chemical Release / Environmental Impact (Off-Site)

Environmental damage due to releases to the air, soil, or bodies of water resulting from hot work related fires, explosions, equipment damage, etc.
Personnel injuries due the release of flammable, combustible vapors, or toxic materials due to products of combustion resulting from hot work related fires.
Personal injuries due to fire escalation or explosions resulting from hot work related fires.

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Technical

Professional/Personal Growth

Societal Needs

Leadership

2024 Center for Hydrogen Safety Americas Conference

PD2M Conference on Modeling and Simulation Applications in Pharmaceutical Development and Manufacturing

Upcoming Conferences & Events

2024 Center for Hydrogen Safety Americas Conference

World Digital Congress of Chemical and Biochemical Engineering

PD2M Conference on Modeling and Simulation Applications in Pharmaceutical Development and Manufacturing

CCPS Latin America Regional Meeting (Spanish)

The Future of AI

2024 Lebanon Student Regional Conference

2024 Greece Chem-E-Car Competition

International Congress on Sustainability Science & Engineering (ICOSSE '24) and RAPID Roadmapping Workshop

2024 Process Development Symposium

CEP: May 2024

CEP: April 2024

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Learning Center:

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Potential Hazardous Consequences

Property Damage (Scaffolding Collapse)

Personal Injury (Safety / Human Health)

Environmental Impact

Property Damage (Scaffolding Collapse)

Personal Injury (Safety / Human Health)

Environmental Impact

Property Damage (Fire / Explosion) – Depending upon the activity being performed

Personal Injury (Safety / Human Health) – Depending upon the activity being performed

Property Damage (Fire / Explosion) – Depending upon the activity being performed

Personal Injury (Safety / Human Health) – Depending upon the activity being performed

Personal Injury (Safety / Human Health)

Property Damage (Fire / Explosion)

Chemical Release / Environmental Impact (On-Site)

Chemical Release / Environmental Impact (Off-Site)

Personal Injury (Safety / Human Health)

Property Damage (Fire / Explosion)

Chemical Release / Environmental Impact (On-Site)

Chemical Release / Environmental Impact (Off-Site)

Property Damage (Fire / Explosion)

Personal Injury (Safety / Human Health)

Chemical Release / Environmental Impact (On-Site)

Chemical Release / Environmental Impact (Off-Site)

Property Damage (Fire / Explosion)

Personal Injury (Safety / Human Health)

Chemical Release / Environmental Impact (On-Site)

Chemical Release / Environmental Impact (Off-Site)

Potential Hazardous Consequences

Personal Injury (Safety / Human Health)

Property Damage (Fire / Explosion)

Chemical Release / Environmental Impact (On-Site and Off-Site)

Potential Hazardous Consequences

Personal Injury (Safety / Human Health)

Property Damage (Fire / Explosion)

Chemical Release / Environmental Impact (On-Site and Off-Site)

Property Damage (Fire / Explosion)

Personal Injury (Safety / Human Health)

Chemical Release / Environmental Impact (On-Site)

Chemical Release / Environmental Impact (Off-Site)

Property Damage (Fire / Explosion)

Personal Injury (Safety / Human Health)

Chemical Release / Environmental Impact (On-Site)

Chemical Release / Environmental Impact (Off-Site)

Property Damage (Fire / Explosion) – While performing Hot Work in an Excavation

Personal Injury (Safety / Human Health)

Property Damage (Fire / Explosion) – While performing Hot Work in an Excavation

Personal Injury (Safety / Human Health)

Some things to consider:

Some things to consider:

Potential Hazardous Consequences

Property Damage (Fire / Explosion)

Personal Injury (Safety / Human Health)

Chemical Release / Environmental Impact (On-Site)

Chemical Release / Environmental Impact (Off-Site)

Potential Hazardous Consequences

Property Damage (Fire / Explosion)

Personal Injury (Safety / Human Health)

Chemical Release / Environmental Impact (On-Site)

Chemical Release / Environmental Impact (Off-Site)