Deliverable D11: Software Tool Risk Analyzer (beta)
Contents
1. Phone 433168737811 Mobile Eee Fax 433168737305 Email friedrich lettner tugraz at Homepage Jwww iwetugraz at Performance data Thermal power 00 00 kwh volume flow producer gas fis0o00 CS m3 th Electrical power foo i kw Heating value producer gas so MJ m Fuel power aooo 080F t CS kw Fuel Biomass mass flow foo F kay h H Control New Process unit Delete Fig 2 Basic Data of the project and the gasification plant Revision 1 0 DRAFT VERSION 8 25 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 4 2 Definition of process units The next step is the definition of process units The procedure is 1 Click Basic Data in the Project Tree Left part of the screen 2 Click New Process Unit in the Control area of basic data window bottom left 3 Create new process unit Each process unit must have a name and a code The code can be taken e g from the piping and instrumentation diagram for example P amp I diagram jsj zioz Fig 3 New process unit elsi ioi x ProjectTree Example_Project Process unit ii Basic Data Name of Process unit 0 Fuel Storage 1 Fuel Feeding and Drying Code 2 Gasifier Description of Process unit 3 Cyclone and Gas Cooling 4 DeDusting 5 Gas Scrubber 6 Gas Conditioning and2. Change operating modes E 5 Gas Scrubber E amp Gas Scrubbing and Transport 1 Quench 2 Scrubber Tank Events Consequences 3 Packing Material Consequence 4 Scrubbing column Concentration too high low _ Explosion CO sensor Failure blocking C Immission exhaust flue gas and smell odour gt Risk Assessment Failure corrosion C Danger to health irritation of skin mucous me Countermeasures Failure electric plant steering and control _ Failure of flare Emergency gas utilisation 2 Te Summary Fahre electric en supply C Mechanic Failure Ge NEW aure eecirica cevice C Failure of automation system E C Danger to health skin burns 8 Scrubbing Media Circulation Failure icina BB een u Scrubbing Media Recirculation and New avert a New Consequence a x 8 Scrubbing Media Treatment 6 Gas Conditioning and Transport 7 Gas Engine 8 Flare Burn off r Add and Delete Events and Consequences Fe E Fe cneccneseneceeseemeneeesneenecsnemeneensemuessneemessnecomesnessnmesnssnnmenscsnemanssncemusssnees Risk Assessment Evert annotation Consequences OOOO Ip Ts e I cmom PEE E e a E SPOREN OTE BE Leakage gas escape air intake Failure of flare Emergency gas utilisation AARP Leakage scrubbing agents Mechanic failure Leakage gas escape air intake Danger to health Leakage gas escape air intake Failure gas engine Emergency sto
3. E ProjectTree Example_Project Function Al Basic Data Name 0 Fuel Storage 1 Fuel Feeding and Drying 2 Gasifier 3 Cyclone and Gas Cooling NEW 4 DeDusting Change operating modes 5 Gas Scrubber a Gas Scrubbing and Transport New Consequences Risk Assessment Event Consequence W Countermeasures Concentration too high low Failure of automation system op Summary Failure blocking U smouldering fire 8 amp Scrubbing Media Circulation Se f gen steering and control z Danger to health siin burns H es Scrubbing Media Recirculation and C Immission exhaust flue gas and smell odour Failure electric power supply Fai ailure gas engine Emergency sto Scrubbing Media Treatment Failure electrical device Failure Flar f ed erg zu g z FEF Hon 6 Gas Conditioning and Transport Failure fittine ar Flanna 7 Gas Engine New event l Ed New Consequence z 8 Flare Burn off NEW Code r Add and Delete Events and Consequences Po Risk Assessment Event Annotation Consequences p s Resut cm yin Probability Severity Result please choose frequency please choose severity I I Save 1 I I gt Save Data Delete Fig 9 The risk assessment window 5 2 Definition of events and consequences and risk assessment The user can define an unlimited numbe
4. from the risk assessment window On the left side you will find your original operating modes On the left side you can define new operating modes If you want to copy one original mode to the left side click into the mode and press the Copy button W Change operating modes ioj xi The original operating modes are on the left side On the right side you can describe changed operating modes IF you want to copy data from the left to the right side select a textfield an push the copy button Original operating modes New operating modes Normal rode Normal mode Original operating mode Start Up Start Up Original Start Up mode Shut Dowun Shut Down Original Shut Down mode Emergency stop Emergency stop Original Emergency stop mode Save or copy operating modes Save Copy Close Fig 12 Change operation modes window Changes in the operation mode will be part of the documentation of the risk analysis which will be generated at the summary window project tree for each process function Revision 1 0 DRAFT VERSION 17 25 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 5 3 Countermeasures For all pairs of events and consequences that were assigned for countermeasures can be taken in the window Countermeasures The procedure of setting countermeasures is shown in the following 1 Selection of the event consequence 2 Creation of the countermea
5. here When you select a database you can create or delete projects and choose the one you want to work on Databases Available databases New Database Delete Database Example Project Test Rig TU Graz Example Scrubber TU Graz Create Project Open Project Delete Project Fig 1 Front Screen Database and project management After opening a project here Example Project the basic information of the project and the evaluated gasification plant can be filled in into the window Basic Data Fig 2 Data for manufacturer operator and the plant power and performance are requested Data is saved with the button Save Data RiskAnalyser beta Example_Project Kal lol x ProjectTree Example_Project Basic Data Jai Basic Data m Plant manufacturer 0 Fuel Storage Company tu Graz Contact Jor Lettner 1 Fuel Feeding and Drying 2 Gasifier Street Inffeldgasse No 25 B 3 Cyclone and Gas Cooling City Graz Zip Code 8010 4 DeDusting fean 5 Gas Scrubber Country Austria 3 6 Gas Conditioning and Transport Phone 43 316 873 7811 Mobile l 7 as Engine Fax 43 316 873 7305 Email friedrich lettner tugraz at 8 Flare Burn off Homepage www iwt tugraz at Plant name Test Rig TU Graz Example Scrubber Manufacturer Operator r Plant operator Operator Tua ti i C CO Contact Dr ee Street Inffedgase No ae o city eaz S S pCode feon Country Austria
6. operation of the automation system assume a functioning process electric system f i unpredictable failure from plant sensor could lead to an total or part wise failure of the automation system Possible dangers to health and impact on environment are summarised within this rubric Fire and explosion are apart from danger to health or environment consequences with an almost always high severity This type of consequence requires in most of cases counter measures and an extended safety concept for successful risk reduction see risk assessment Functions failure means the occurance of and specific function of the investigated unit or sub unit which leads to fatal errors in the process chain DRAFT VERSION 24 25 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 9 Annex B Examples for Function summary Function Summary Name Gas Scrubbing and Transport C1 Function Description Ong inal operating modes Normal mode Start Up Shut Down Emergency stop RiskAssessment Event Leakage gas escape air intake Annotation Consequence Name Danger to health Risk Final Risk Consequence Name Failure of flare Emergency gas utilisation Risk Final Risk Consequence Name Poisoning Risk Countermeassures Name CO monitoring Category technical Description New Risk Final Risk ALARP Revision 1 0 DRAFT VERSION 25 25
7. that may be made of the information contained therein Whilst every effort has been made to ensure the accuracy of this document the author cannot accept and hereby expressly excludes all or any liability and gives no warranty covenant or undertaking whether express or implied in respect of the fitness for purpose of or any error omission or discrepancy in this document and reliance on contents hereof is entirely at the user s own risk Revision 1 0 DRAFT VERSION 3 25 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 1 Software tool RISK ANALYSER 1 1 Objective and target group The generation of the software tool is part of the Gasification Guide project EIE 06 078 1 with the objective to accelerate the market penetration of relatively small scale biomass gasification systems lt 5 MWe ue for the decentralises energy supply systems based on renewable sources Together with the development of a guideline the software tool facilitates the assessment of health safety and environment HSE issues of small scale biomass gasification plants The target group of the software tool are in the first place operators manufacturers project developers researchers and implementers of biomass gasification plants Since the software is created generally open in order to be used for any gasification technology and process chain compare with the technology description in the guideline also gener
8. Transport 7 Gas Engine 8 Flare Burn off NEU M Process units Process unit 0 Fuel Storage 1 Fuel Feeding and Drying 2 Gasifier 3 Cyclone and Gas Cooling 4 DeDusting S Gas Srruhher Control New Function Save Data Delete Fig 4 Example for the definition of process units for a typical gasification plant A selected function can be deleted by the usage of the delete button Warning The Delete Button removes the selected data irrecoverable A undo function is not implemented If the foremost process unit is selected and deleted all sub items and information will be lost Revision 1 0 DRAFT VERSION 9 25 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 4 3 Definition of functions for each process unit Every process unit is subdivided into functions To define new functions the procedure is 1 Click on the respective process unit for which the function should be defined e g Gas Scrubber in the project tree Click New Function control area of process unit window bottom left Create new function Assign name and code at least Press Save Data he ws This is shown for the process unit Gas Scrubber in Fig 5 where the following functions were defined exemplarily e Gas scrubbing and transport e Scrubbing media circulation e Scrubbing media treatment e Scrubbing media recirculation and waste water treatment Again functions mu
9. asures from the RiskAssesment Record resulting operating 0 Fuel Storage mode changes here 1 Fuel Feeding and Drying 2 Gasifier 3 Cyclone and Gas Cooling 4 DeDusting 5 Gas Scrubber Gi Gas Scrubbing and Transport 1 Quench Start Up 2 Scrubber Tank Original Start Up mode 3 Packing Material 4 Scrubbing column CO sensor Shut Down gt Risk Assessment Original Shut Down mode WU Countermeasures To Summary u NEW Emergency stop d Scrubbing Media Circulation Scrubbing Media Recirculation and Scrubbing Media Treatment 6 Gas Conditioning and Transport 7 Gas Engine New operating modes 8 Flare Burn off Normal mode Original operating modes Countermeasures Normal mode ogoan Original operating mode CO monitoring m E Original Emergency stop mode 5 F Start Up Shut Down Emergency stop r Control Create Report Fig 15 Reporting of Risk assessment with countermeasures applied The summary report is generated as a pdf document in lt ProgramFolder gt reports with the name Reports _ lt FunctionName gt and consists of the following points e Name e Function description e Original operation modes e Unit descriptions o General description o Design parameters o Auxiliary media with media parameter e all units e Risk Assessment e Events and consequences sorted by ev
10. ated in this project it can moreover also be used for other processes than biomass gasification 1 2 Method From literature there are many possible approaches regarding risk assessment procedures available 2 4 The substantial differences between these methods often lie in the basic approach and the degree of exactness of the reachable results Biomass gasification in small and medium scale systems is partly a unique technology where no explicit techniques and no guidance for the conduction of risk assessment are available This software provides a recommended risk assessment procedure which is practicable and sufficient for the application in biomass gasification plants The chosen method bases on a HAZOP study and is enlarged by additional features which are demanded by the application in biomass gasification plants The method for the risk assessment which is implemented in this software tool is described in detail in other reports of the project and in the draft guideline as well as in the final guideline later on 1 3 Required preparation and documents by the user group Risk identification and assessment is a very extensive work where one needs to be aware of the process its behaviour and the risk assessment methodology itself A general suggestion is that risk assessment should be done in team work since creativity is enhanced and oversight of possible hazards can be reduced Prior to starting the software aided risk assessment th
11. ccseeceeeeeeeeeeeeeeteeteeneeens T 4 Definition of the process and the gasification plant ccc eecceeceeeeceeeeeeeeeeeeeeseeeseeeees 7 4 1 Project selection and management cccecceeecesecceeceeecaeecececeeeceeceeeseeeseeeseeeseeenes 7 4 2 Definition OF Process Units u us nee 9 4 3 Definition of functions for each process unit 2zu0220022002n0nnnennnennnennn nennen 10 4 4 Definition of units for each FUNCTION u02220022002snenennnnnnennnn nenne nnne nennen 11 4 5 Definition of design parameters of units u022002220020n0nnnnennnenennnnenenenen nennen 12 4 6 Definition of auxiliary media for units 200220002200nenennnnennnenennn nenn nenne ennnnen 13 9 RISK ANANSIS Ara ee ee een 15 5 1 RISK analysis WINGOW n ae niit rin 15 5 2 Definition of events and consequences and risk assessment ccceeee seen eeeeees 15 3 83 GOUNlerMeasures a n nn een Snadesententaeemiamiaterieae 18 DB REDOTINGe Ares 19 6 1 Summary Or each TUNCHON ston een Es 19 6 2 REDOFLUING IMGenerales sa 20 T REIELENEES onsa a a AE 21 8 Annex A Default list of events and consequences cccceccceecceeeeeeeeeeeeeeeeeteeeeneenes 22 9 Annex B Examples for Function summary u0222002200ssnunnnnenenennnennnnnnnnennnnnnnn nennen 25 Revision 1 0 DRAFT VERSION 2 25 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide Fore
12. e following points should be prepared e plant data process schemes piping and instrumentation diagram P amp I plant part reference designation codes apparatuses design etc e predefined plant operation modes knowledge about start up shut down and normal operation mode process control strategies e desired operation conditions temperature pressure flows and expected gas compositions e machinery lists details construction drawings e mass and energy balances process stream information composition and pollutant load Revision 1 0 DRAFT VERSION 4 25 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide The above process information should reasonable be fed into the software by a single person before starting the risk assessment by the team 2 Installation and system requirements 2 1 System requirements The software RISK ANALYSER is programmed for the Java runtime environment Java has to be installed in order to run RISK ANALYSER The system requirements are e Intel Pentium Ill or equivalent processor e Microsoft Windows Vista Windows XP or Tablet PC Edition Microsoft Windows 2000 512 MB of RAM e Java runtime environment download Java from http www java com en download Since Java is platform independent the software will be available for all other operating systems in the future 2 2 Installation procedure RISKANALYSER comes with a multi language self in
13. e shortcut C Dokumente und Einstellungen haselbacher Startmen lProgramm Output Folder C Programme Risk nalyser J Click Finish to close this wizard Create shortcut C Dokumente und Einstellungen haselbacher Startmen lProgramm Completed Nullsoft Install System v2 33 Back i Gancel Revision 1 0 DRAFT VERSION 5 25 Software Tool RISK ANALYZER beta 2 3 Start Programme User manual The programme Risk Analyser can be started via Start Programs RiskAnalyser RiskAnalyser Po This website provides information on Health Safety anc Publications Environmental aspects of biomass gasification plants Il i designed and constructed for owners of gasification plar Deliverables 5 manufacturers project developers investors researche Events implementers of biomass gasification systems pm The objective is to accelerate the market penetration of l What s new 2 eee A a es small scale biomass gasification systems lt 5 MW ther amp Programmzugriff und standards Glossary of basic terms development of a Guideline and Software Tool for eas g Neues Office Dokument 0g Office Dokument ffnen Programme gt an Studio 8 an Zubeh r 73 Dokumente gt fan Eh 77 Ausf hren Windows XP Home Edition Herunterfahren inke simple risk assessment of HSE Windows Update Gasification Guide is a project supported by the Intellic eo Oita a
14. easure Unit Name co Sensor Code Create Unit Control Save Data Fig 13 Setting of countermeasures Technical countermeasures may involve new units plant parts These units can easily be created at the bottom of the countermeasures window At the end of the risk assessment when you enter the Summary window the user is asked whether the new assigned units have also been considered and evaluated in the risk analysis see Fig 14 Unit considered x 7 Did you take into account the unit you created as countermeasure 7 Unit CO sensor 500 Fig 14 Question dialog for consideration of new units Revision 1 0 DRAFT VERSION 18 25 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 6 Reporting 6 1 Summary for each function At the present beta version reports can be automatically generated for each function A so called Function summary is generated by pressing the create report button in the lower part of the screen Again operating modes new after changes through risk analysis can be edited in this window Additionally also a list of all countermeasures for risk minimizations is given at the right side of the window RiskAnalyser beta Example_Project _ oj x ProjectTree Example_Project Info lal Basic Data Here you find the Function operating modes and the counterme
15. ecessary by pressing the button Add Medium Parameter Fig 8 shows the dialog window for the creation and assignment of auxiliary media for units The procedure is as follows 1 Creation of anew medium at the field to the right in the Medium group e g Description Water content producer gas and Unit vol H gt O_dry basis Pressing the lt button will add the new medium stream to the drop down list of stream to the left hence to the selected unit Revision 1 0 DRAFT VERSION 13 25 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide Streams can be assigned with parameters in the following way 1 Selection of a media from the drop down list 2 Selection of a media parameter in the list 3 By pressing the Add Parameter Button the parameter will be added to the media parameter list in the bottom of the screen hence to the selected media 4 New parameters can be created in the fields to the right description and unit and pressing the lt button will add them to the media parameters list left 5 Alternatively media parameters can be deleted by the button W Auxiliary media 1 Quench O x Here you can choose an existing auxiliary media or create a new one Then you can add new parameters to ik You can alsa create and delete Parameters Medium Scrubbing water Parameter Fluid Description pressure es 4 rH walue Eu viscosity kinematic l Unik lower heating val
16. een Intelligent Energy Me Europe Grant agreement no EIE 06 078 S12 447511 Project acronym Gasification Guide Full title of the action Guideline for safe and eco friendly biomass gasification Intelligent Energy Europe IEE Key action ALTENER Deliverable D11 Software Tool Risk Analyzer beta User Manual Software Beta version November 2007 12 10 DRAFT VERSION Author Friedrich Lettner Peter Haselbacher Helmut Timmerer Markus Seebacher Institute of Thermal Engineering Graz University of Technology Inffeldgasse 25B A 8010 Graz sterreich Austria www www iwt tugraz at The project is co funded by the European Commission Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide Table of Contents Tale Ol GConlenB zen seele 2 FOR WORT a Er nn ee REN oa EA A acmadees 3 1 Software tool RISKANAEYSER zung 4 1 1 ODIECIVE ANG Target groups een ee 4 1 2 MSMO Ge ee se a E ee 4 1 3 Required preparation and documents by the user QrOup ccceccceeeeeeeeeeeeeeeees 4 2 Installation and system requirements c cece ce eee ceeeceeeeeeeeeeeeeece esse eeseeeseeeseeeseeeaeeseeess 5 2 1 SYstem requirements sarah aeateceswent 5 2 2 M Stalai on Procedure nenne a aa 5 9 Gen raldeserplions unserer T 3 1 Structure and hierarchy of the implemented database 222002202220 22200 T 3 2 Reference designation function and unit codes cccce
17. eft Create new unit Assign name and code at least Press Save Data This is shown for the function Gas Scrubbing and Transport in Fig 6 where the following units were defined exemplarily e Quench e Scrubber Tank e Packing material e Scrubbing column WRiskAnalyser beta Example Project ioii ProjectTree Example_Project Unit nern dal i 1 Fuel Feeding and Drying i 2 Gasifier Basic Data an PT 1 0 Fuel Storage Code Ol Design parameters 1 3 Cyclone and Gas Cooling i 4 DeDusting Import parameters from unit Add design parameter Delete design parameter Just load ee Name nk Min Normal Max i sg Gas Scrubbing and Transport 5 0 1 Quench pressure 2 Scrubber Tank pressure drop 1 3 Packing Material temperature 120 0 4 Scrubbing column F OO sensor Auxiliary media Overview I Risk Assessment Import auxiliary media from unit pel Countermeasures g Solid Add Mediumi Parameter Delete Medium Parameter Fa Summary rew Hg Scrubbing Media Circulation H Scrubbing Media Recirculation and a Scrubbing Media Treatment J J 6 Gas Conditioning and Transport Add Medium Parameter Delete Medium Parameter 7 Gas Engine Scrubbing water Gaseous Add Medium Parameter Delete Medium Parameter me O o i 1 7 ProducerGas_afterFabFilter Control Save Data Delete Fig 6 Definition of units for the function Gas Scrubbing and Transport exemp
18. ents Revision 1 0 DRAFT VERSION 19 25 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide o If countermeasures were applied these are documented and the improvement of the risk before and after is shown see Fig 16 RiskAssessment Event Leakage gas escape air intake Annotation Consequence Name Danger to health Risk Final Risk Consequence Name Failure of flare Emergency gas utilisation Risk Final Risk Consequence Name Poisoning Risk Countermeassures Name CO monitoring Category technical Description New Risk Final Risk ALARP Fig 16 Reporting of Risk assessment with countermeasures applied 6 2 Reporting in general Annotation of the programmer In the area of reporting there is still big potential for improvement of this beta version of the RISK ANALYSER Principally the underlying framework allows great flexibility in the design of the reporting sheets and the file formats pdf xml rtf etc Recommendations are highly welcome Revision 1 0 DRAFT VERSION 20 25 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 7 References 1 2 3 4 9 6 Gasification Guide Guideline for safe and eco friendly biomass gasification project no EIE 06 078 www gasification guide eu in process Steinbach J Antelmann O Lambert M Methoden zur Bewertung des Gefahrenpotentials von verfahrenstech
19. in Norm Max values to your parameter a Design parameters can easily be imported from existing settings done for other units Button Import parameter from unit in the unit window Deleting of parameters can be done via the delete button Warning The Delete Button removes the selected data irrecoverable A undo function is not implemented Revision 1 0 DRAFT VERSION 12 25 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide W Design parameters Oo x Create Delete design parameter concentration of organic compounds Description concentration of organic compounds mg L dust load Pprn_m water content producer gas dust load ppm dust load mgs _n Unik mass flow m _r h mass Flow kg h volt H20 _dry basis pressure hFa Pressure bar Create new design parameter pressure drop Pa pressure drop mbar temperature i Delete design parameter temperature k temperature IE water content Soy dryvbasis Add design parameter to unit Add Close Here you can add design parameters to your unit create new parameters and delete them Fig 7 Definition of design parameters for units plant parts 4 6 Definition of auxiliary media for units The user can define an unlimited number of auxiliary solid liquid and gaseous media i e process streams for each unit plant part and assign parameters to them Any process streams can be added by the user as n
20. larily Revision 1 0 DRAFT VERSION 11 25 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide Again units must have a name and a code Units can be assigned with design parameters and auxiliary media solid liquid and gaseous Exemplarily these data for unit Quench are shown in Fig 6 as well Design parameter for unit quench e g temperature Min 75 C Normal 90 C Max 120 C Auxiliary media Liquid scrubbing water Gaseous producer gas after fabric filter after process unit de dusting 4 5 Definition of design parameters of units The user can define an unlimited number of design parameter for each unit plant part By default there is a list of typical design parameters temperature pressure pressure drop tar and particle load in the producer gas to choose from Any other design parameters can be added by the user as necessary by pressing the button Add design parameter Fig 7 shows the dialog window for the creation and assignment of design parameters The procedure is as follows 1 Creation of a new parameter at the fields to the right e g Description Water content producer gas and Unit vol H2O_dry basis Pressing create new design parameters will add the new parameter to the list of default design parameters at the left 2 Selection of a design parameter in the list By pressing the Add Button the parameter will be added to the Unit window 4 Apply M
21. nischen Anlagen Schriftenreihe der Bundesanstalt f r Arbeitssschutz und Arbeitsmedizin Berlin Dortmund 1991 Steen H Handbuch des Explosionsschutzes Wiley VCH Willingdon England 2000 K hnreich K Bock F J Hitzbleck R Kopp H Roller U Woizischke N Ermittlung und Bewertung des Gefahrenpotentials f r Besch ftigte in verfahrenstechnischen Anlagen und Lagereinrichtungen Berlin Dortmund 1998 DIN 6779 10 Kennzeichnungssystematik f r technische Produkte und technische Produktdokumentation Teil 10 Kraftwerke 2007 04 EN 61346 1 Industrial systems installations and equipment and industrial products Structuring principles and reference designations Part 1 Basic Rules 1998 01 14 Revision 1 0 DRAFT VERSION 21 25 Software Tool RISK ANALYZER beta User manual 8 Annex A Default list of events and consequences Table I Default list of events 1 OD O1 A OIN 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 name Leakage gas escape air intake Leakage steam Leakage liquids escape Leakage scrubbing agents Leakage solids Temperature too high low Pressure too high low Plant flows too high low Plant fill level too high low Concentration too high low Failure mechanical stress Failure thermal stress Failure corrosion Failure icing Failure ware out Failure blocking Failure sealing Failure welding Failure fitting or flange Hot surfaces Failure electric
22. ows Media Player Suchen GH RiskAnalyser IF Loop Recorder Co Hilfe und Support y Ausf hren Windows XP Home Edition Herunterfahren ed Windows Katalog Member login intelligent Energy Europe simple risk assessment of HSE Gasification Guide is a project supported by the Intelligen for Europe programme under contract no EIE 06 078 The project is supported by Intelligent Energy 0 Europe AE Uninstall RiskAnalyser Figure 2 2 Windows Start menu for uninstalling the Riskanalyser DRAFT VERSION EIE 06 078 Gasification Guide 6 25 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 3 General descriptions 3 1 Structure and hierarchy of the implemented database During the definition of the process and the gasification plant the following hierarchy has to be used 1 Process units top 2 Functions of a process unit 3 Units needed to fulfil a function and so belonging to the function For better clarity the whole process has to be divided into process units e g gasifier or gas scrubbing Every process units is subdivided into functions e g cooling of the gas Subsequently units i e plant parts are assigned for each function 3 2 Reference designation function and unit codes Each process function and unit is designated in the software tool by a code It is recommended to use a structured designation sy
23. p Frequency Severity Result casual disastrous UNACCEPTABLE I I I Control Save Data gt Delete Fig 10 Definition of events and consequences According to the combination of probability i e frequency and severity a risk is associated to each pair of event and consequence The risk can be ok alarp or unacceptable Alarp stands for as low as reasonable possible The implemented risk matrix is shown in Fig 11 Unacceptable risks have to be removed by a countermeasure Other risks may also be lowered by counter measures lf a counter measure will be set the shield symbol has to be activated in the CM y n column For unacceptable risks this is activated obligatory As long as there are unacceptable risks within a process function no summary can be created Revision 1 0 DRAFT VERSION 16 25 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide frequent probable casual Frequency imaginable improbable unthinkable inessential marginally critical disastrous Effects Severity acceptable region ALARP region As Low As Reasonably Practicable Region unacceptable region Fig 11 Risk matrix of frequency vs severity During risk assessment changes in the plant operation may be necessary These adoption can be described in the Change operation modes window see Fig 12 which can be accessed
24. power supply Failure electric plant steering and control Failure electrical device Failure sensor Revision 1 0 description The term leakages includes the types of unpredictable loss of containment of plant media and plant utilities Plant media could be biomass producer gas scrubbing agent etc Plant utilities are possibly pressurised air cooling agents inertisation media like nitrogen etc Physical chemical parameters gives defined operation conditions of the particular investigated functional group an exceeding or undershooting of this normal operation conditions could principally lead to hazards and should therefore be investigated as for too high or too low Part or functional group failure can have various shape depending on operation conditions or mechanical thermal or chemical stress Thermal conversion plants possess system immanent hot surfaces which have to be analysed due to possible hazards f i gasifier gas engine exhaust gas system etc Failure in electrical installations devices or plant steering and control system could be a initial points for a huge number of possible hazards in fully automated plant concepts Therefore a comprehensive analyse on that topic have to be applied according to the listed points of this rubric DRAFT VERSION EIE 06 078 Gasification Guide 22 25 Software Tool RISK ANALYZER beta User manual name 25 Failure plant media utility supply and di
25. r of events and consequences with the fields New events and new consequences respectively The A button residing left to the New event New Consequence text field will add the new event consequence to the list the Y will delete a marked event consequence from the list The next step is the combination of all possible events in the respective process function with possible consequences The procedure is indicated in Fig 10 and explained in the following Revision 1 0 DRAFT VERSION 15 25 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 1 Select the event you want to add by clicking on it 2 Select the consequences you want to add to the event by clicking the checkboxes in the consequences window 3 By pressing the V Button in the Add and Delete Events and Consequences group you add them to the Risk Assessment When the combination is selected blue background it can be evaluated with a risk Selection of a probability slide bar Selection a severity slide bar Save Button oo RiskAnalyser beta Example_Project i iol x ProjectTree Example_Project isi Basic Data Function Name 4 0 Fuel Storage Er CEITEC TTT H 1 Fuel Feeding and Drying 2 Scrubber Tank ST1 z 5 2 Gasifier 3 Packing Material PM1 eae 3 Cyclone and Gas Cooling 4 Scrubbing column SCP scl 4 DeDusting CO sensor
26. s for Europe programme under contract no EIE 06 078 i Member login The project is supported by dam MindManager 2002 a z Intelligent Energy Europe f 2 Microsoft Office mama er Einstellungen gt A EEEN Dr s Windows Media Player x Suchen SGi Risk nalyser O RiskAnalyser IF Loop Recorder r Hilfe und Support x Figure 2 1 Windows Start menu for starting the Riskanalyser 2 4 Uninstall The uninstaller can be reached via Start Programs RiskAnalyser Uninstall RiskAnalyser Revision 1 0 Biomass Gasification aims to effectively tackle this barrier Prog This website provides information on Health Safety and Publications Environmental aspects of biomass gasification plants It is z designed and constructed for owners of gasification plants Deliverables z 5 l manufacturers project developers investors researchers i Events implementers of biomass gasification systems i The objective is to accelerate the market penetration of rel m What s new HER en i small scale biomass gasification systems lt 5 MW thermal Programmzugriff und standards Glossary of basic terms development of a Guideline and Software Tool for easy ai ty Windows Update Links MindManager 2002 3 Neues Office Dokument Be AG Office Dokument ffnen Programme St IF Zubeh r Dokumente gt an Adobe IM Microsoft Office ee Einstellungen Wind
27. sposal 26 Harmful plant media and utilities 27 Transient operation start up 28 Transient operation shut down 29 Transient operation increase plant power load 30 Transient operation emergency shut down 31 Operating error 32 Maintenance 33 Force of nature flooding 34 Force of nature stroke of lightning 35 Force of nature storm thunderstorm 36 Force of nature earthquake Revision 1 0 description The reliable supply with plant medias and plant utilities is necessary for the safe and stable plant operation Failures within the supply chain could lead to transient operation states shut down or failure of safety functions Biomass Gasification plants process different medias and utilities which could be harmful for human health and environment A possible loss of containment see also leakage could directly result in health or environmental impairment Transient plant operation states includes start up shut down and changes of plant power load where grave intervention into the plant control parameters applied by the operator or automatic routines take place Operating error are frequent reasons for hazardous consequences within plant operation so the plant concept should therefore be analysed on such possibilities and further improvement to prevent maloperation process automation technical precaution fail safe Forces of nature have generally to be considered and focuses on the reliability of
28. st have a name and a code For each function a general description is required as well as a description for the plant operation modes verbally in the respective text fields The operation modes are e Normal mode e Start up e Shut down e Emergency stop RiskAnalyser beta Example_Project ejoj Oj x ProjectTree Example_Project Function Fi Basic Data 0 Fuel Storage 1 Fuel Feeding and Drying Function name Code 2 Gasifier Function description 3 Cyclone and Gas Cooling 4 DeDusting 5 Gas Scrubber u Gas Scrubbing and Transport amp Scrubbing Media Circulation M Operating modes wy Scrubbing Media Recirculation an Normal mode Gy Scrubbing Media Treatment 8 6 Gas Conditioning and Transport 7 Gas Engine 8 Flare Burn off NEU E e A Start Up Shut Down Emergency stop r Control E Create Unit Save Data Delete Fig 5 Definition of functions for a process unit Revision 1 0 DRAFT VERSION 10 25 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 4 4 Definition of units for each function Every function consists of units i e plant parts The defining procedure is 1 oY gt aay Click on the respective function for which the unit should be defined e g Gas Scrubbing and Transport in the project tree Click New Unit control area of function window bottom l
29. staller setup exe which is shown for Windows in the following RiskAnalyser Setup azik 3 ioii Choose Install Location TN Choose the folder in which to install RiskAnalyser gt Welcome to the RiskAnalyser Setup Wizard Setup will install RiskAnalyser in the Following Folder To install in a different Folder click Browse and select another folder Click Next to continue This wizard will guide you through the installation of Risk nalyser It is recommended that you close all other applications before starting Setup This will make it possible to update relevant system files without having to reboot your computer Click Next to continue ProgrammelRisk nalyser Browse Space required 32 4MB Space available 6 8GB mm Folder Nullsoft Install System v2 33 lt Back Cancel aaz RiskAnalyser Setup SIE Installation Complete G Completing the RiskAnalyser Setup Setup was completed successfully J9 Wizard Completed Risk nalyser has been installed on your computer Dee a memmzhExm rar Extract ver2 properties 100 Extract ver2 script 100 Extract ver properties 100 Extract ver script 100 Extract C ProgrammelRiskAnalyser swt win32 3347 dll 100 Output Folder C Programme Risk4nalyser Created uninstaller C Programme RiskAnalyser Uninstall exe Output Folder C Dokumente und Einstellungen haselbacher Startmen lProgramme Creat
30. stem according to latest international standardisation for power plants i e IEC 61346 1 Structuring principles and reference designation and the RDS PP reference designation system for power plants respectively 5 6 4 Definition of the process and the gasification plant 4 1 Project selection and management RISK ANALYSER stores all information all projects all default settings etc in one or more database files This file is stored in e g lt ProgramDirectory gt db and is called e g database Any new project will be saved into the selected database given on the starting screen The first screen of RISK ANALYSER allows the management of databases and projects within a database file Fig 1 The procedure is 1 Create delete databases In the background a database will be created or deleted 2 Select and open a database The user has to select the wanted data base via mouse click and opens the database by selecting Open database The different projects maybe different gasification plants within this data base will be shown in the window below 3 Create new project or open or delete an existing project When a data base was activated and open existing project within the data base can be added opened or deleted Revision 1 0 DRAFT VERSION 7 25 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 15x RiskAnalyser Info You can create select and delete new databases
31. sure a Name text field b Selection of a category organizational technical constructive process control strategy c Add d Changing of the probability lowering due to the new countermeasure RiskAnalyser beta Example_Project 4 sjel 5 x ProjectTree Example_Project Info lal Basic Data To create new Countermeasure First choose an Event with it s associated Consequence Then you can define and edit new 0 Fuel Storage countermeasures For technical countermeassures you have to define a new unit too 1 Fuel Feeding and Drying zen 2 Gasifier severe andar nah event Annotation consequences 4 DeDusting Leakage gas escape air intake Poisoning UNACCEPTABLE 5 Gas Scrubber B Gas Scrubbing and Transport 1 Quench 2 Scrubber Tank 3 Packing Material r Create countermeasures 4 Scrubbing column CO sensor Name co monitoring Category technical Add Delete ae Z Risk Assessment U Countermeasures Event 0 0 0 0 nme Categor Description Leakage gas escape air intake CO monitoring technical 5 Risk Assessment oci g Countermeasures 7 Summary H Scrubbing Media Circulation Scrubbing Media Recirculation an Scrubbing Media Treatment 6 Gas Conditioning and Transport Change Probability 7 Gas Engine New probability Result 8 Flare Burn off Gar moderate probability alarp 1 _ ____ Save I i M Create new unit here for technical counterm
32. the process chain under such environmental influences DRAFT VERSION EIE 06 078 Gasification Guide 23 25 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide Table Il Default list of consequences name 1 Abnormal operation conditions 2 Mechanic failure 3 Danger from electricity 4 Failure gas engine Emergency stop 5 Failure of combustion system 6 Failure of flare Emergency gas utilisation 7 Failure of automation system 8 Danger to health 9 Danger to health skin burns 10 Danger to health irritation of skin mucous membrane 11 Noise pollution ototoxic noise 12 Immission exhaust flue gas and smell odour 13 Poisoning 14 Smouldering fire 15 Fire 16 Explosion 17 Failure of function 18 others Revision 1 0 description Abnormal operation conditions are typically described by exceeding undershooting of normal operation conditions and physical chemical media properties and can have various reason This term contains various types of possible failure and failure reasons see also event list Danger from electricity includes hazards where electrical installation and their possible malfunctions are involved Biomass conversion plants gasification combustion process solid liquid and or gaseous fuels and have to guarantee a safe utilisation of varying feedstock and under different plant operation states normal operation start up shut down etc The stable
33. ue LHW viscosity dynamic Pressure density hazardous substance classification Add Parameter Delete Parameter Close pH alue temperature A Fig 8 Definition of auxiliary media streams for units plant parts After closing the window the user returns to the unit window Here media parameters can easily be imported including their properties media parameters from existing settings done for other units Button Import auxiliary media from unit in the unit window Deleting of parameters can be done via the delete parameter button Warning The Delete Button removes the selected data irrecoverable A undo function is not implemented Revision 1 0 DRAFT VERSION 14 25 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 9 Risk analysis 9 1 Risk analysis window Fig 9 shows the risk assessment window Risk assessment has to be applied for each process function here gas scrubbing and transport which is selected in the project tree left In the upper part of the window a list of all parts which belong to the selected function is shown In the lower part of the window lists for events and consequences can be created The default database contains a list of 36 events and 17 preset consequences which can be extended by each user as necessary These two lists can be found in Annex A to this manual Table and Table Il RiskAnalyser beta Example_Project f
34. word The software tool RISK ANALYSER was created in 2007 under the Gasification Guide project which is supported by the Intelligent Energy for Europe programme under contract no EIE 06 078 Biomass gasification is a promising technology which can contribute to the overall EU policy to develop future energy systems which are efficient safe in design and operation as well as environmental friendly and increase the share of renewable energy Gasification technology is near to commercialisation but today large scale introduction is hampered by various reasons Poor awareness and lack of understanding of the Health Safety and environment HSE hazards in the project development planning design construction stage and during operation and maintenance of gasification plants is recognized as a major non technical obstacle The project Guideline for Safe and Eco friendly Biomass Gasification aims to effectively tackle this barrier The objective is to accelerate the market penetration of relatively small scale biomass gasification systems lt 5 MWruc by the development of a Guideline and Software Tool for easy and simple risk assessment of HSE The project homepage can be reached at http www gasification guide eu Legal Disclaimer The sole responsibility for the content of this report lies with the author It does not necessarily reflect the opinion of the European Communities The European Commission is not responsible for any use
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