Safety report assessment guidance (technical aspects)
The Safety Report should show a clear link between the measures taken and
the major accident hazards described.
Relevant Technical Measures Documents
The Safety Report should demonstrate how the measures taken will prevent
foreseeable failures, which could lead to major accidents.
Relevant Technical Measures Documents
Criterion 5.2 has been subdivided into lower level criteria, and has been
grouped, and can be found on the following pages
This includes the following Criteria:
- Criterion 5.2.1.1
The Safety Report should show that the establishment and
installations have been designed to an appropriate standard.
- Criterion 5.2.1.2
The Safety Report should show that a hierarchical approach to the selection
of measures has been used.
- Criterion 5.2.1.3
Layout of the plant should limit the risk during operations,
inspection, testing, maintenance, modification, repair and replacement.
- Criterion 5.2.1.4
Utilities that are needed to implement any measure defined in
the safety report should have suitable reliability, availability and
survivability.
- Criterion 5.2.1.5
The Safety Report should show that appropriate measures have
been taken to prevent and effectively contain releases of dangerous
substances.
- Criterion 5.2.1.6
The Safety Report should show that all foreseeable direct causes
of major accidents have been taken into account in the design of the
installation.
- Criterion 5.2.1.7
The Safety Report should show how structures important to safety
have been designed to provide adequate integrity.
- Criterion 5.2.1.8
The Safety Report should show how the containment structure
has been designed to withstand the loads experienced during normal
operation of the plant and all foreseeable operational extremes during
its expected life.
- Criterion 5.2.1.9
The Safety Report should show that materials of construction
used in the plant are suitable for the application.
- Criterion 5.2.1.10
The Safety Report should show that adequate safeguards have
been provided to protect the plant against excursions beyond design
conditions.
- Criterion 5.1.2.11
The Safety Report should describe how safety-related control
systems have been designed to ensure safety and reliability.
- Criterion 5.2.1.12
The Safety Report should show how design systems, which require human
interaction have been designed to take into account the needs of the
user and be reliable.
- Criterion 5.2.1.13
The Safety Report should describe the systems for identifying
locations where flammable substances could be present and how the
equipment has been designed to take account of the risk.
The Safety Report should show that the establishment and installations
have been designed to an appropriate standard.
Relevant Technical Measures Documents
Relevant Documentation and Case Studies for Criterion 5.2.1.1
|
Design for Containment |
Documentation
- EH70 The control of fire-water run-off from CIMAH sites to
prevent environmental damage
- HS (G) 28 Safety advice for bulk chlorine installations
- HS (G) 176 The storage of flammable liquids in tanks
Case Studies
|
|
Design for redundancy |
Documentation
- IEC 61508 Functional safety of
electrical/electronic/programmable electronic safety-related
systems
- HS (G) 28 Safety advice for bulk chlorine installations
Case Studies
|
|
Segregation |
Documentation
- HS (G) 71 Chemical Warehousing: the storage of packaged
dangerous substances
- HS (G) 176 The storage of flammable liquids in tanks
- LPGA CoP 1 Bulk LPG storage at fixed installations. Part 1:
Design, installation and operation of vessels located above ground
Case Studies
|
The Safety Report should show that a hierarchical approach to the selection
of measures has been used.
Relevant Technical Measures Documents
Relevant Documentation for Criterion 5.2.1.2
|
Inherent Safety |
Documentation
- HS (G) 28 Safety advice for bulk chlorine installations
- HS (G) 30 Storage of anhydrous ammonia under pressure in the UK:
spherical and cylindrical vessels
- HS (G) 140 Safe use and handling of flammable liquids
- HS (G) 176 The storage of flammable liquids in tanks
- HS (G) 190 Preparing safety reports: Control of Major Accident
Hazards Regulations 1999
- LPGA CoP 1 Bulk LPG storage at fixed installations. Part 1:
Design, installation and operation of vessels located above ground
|
Layout of the plant should limit the risk during operations,
inspection, testing, maintenance, modification, repair and replacement.
Relevant Technical Measures Documents
Relevant Documentation and Case Studies for Criterion 5.2.1.3
|
Layout |
Documentation
- API RP 752 Management of hazards associated with location of
process plant buildings
- BS 5908: 1990 Code of practice for fire precautions in the
chemical and allied industries
- CIA Guidance for the location and design of occupied building on
chemical manufacturing sites
- HS (G) 28 Safety advice for bulk chlorine installations
- HS (G) 30 Storage of anhydrous ammonia under pressure in the UK:
spherical and cylindrical vessels
- HS (G) 176 The storage of flammable liquids in tanks
- IGE SR 14 High pressure gas storage: Part 1 - Above ground
storage vessels
- LPGA CoP 1 Bulk LPG storage at fixed installations.
Case Studies
|
Utilities that are needed to implement any measure defined in the
safety report should have suitable reliability, availability and
survivability.
Relevant Technical Measures Documents
Relevant Documentation and Case Studies for Criterion 5.2.1.4
|
Utilities |
Documentation
- BS 5908:1990 Code of practice for fire precautions in the
chemical and allied industries
- HS (G) 28 Safety advice for bulk chlorine installations
- HS (G) 39 Compressed air safety
- HS (G) 103 Safe handling of combustible dusts: precaution
against explosions
Case Studies
|
The Safety Report should show that appropriate measures have been
taken to prevent and effectively contain releases of dangerous substances.
Relevant Technical Measures Documents
Relevant Documentation and Case Studies for Criterion 5.2.1.5
|
Containment Control |
Documentation
- ASME BS 31.3 Process piping: 1999
- BS 7777:1993 Flat-bottomed, vertical, cylindrical storage tanks
for low temperature service
- EEMUA 147 Recommendations for the design and construction of
refrigerated liquefied gas storage tanks
- HS (G) 28 Safety advice for bulk chlorine installations
- HS (G) 176 The storage of flammable liquids in tanks
- HS (G) 186 The bulk transfer of dangerous liquids and gases
between ship and shore
- EH70 The control of fire-water run-off from CIMAH sites to
prevent environmental damage
Case Studies
|
|
Venting |
Documentation
- API Std 2000 Venting atmospheric and low pressure storage tanks:
Non refrigerated and refrigerated
- BS 2915:1990 Specification for bursting discs and bursting disc
devices
- HS (G) 158 Flame arresters: preventing the spread of fires and
explosions in equipment that contains flammable gases and vapours
- LPGA CoP 1 Bulk LPG storage at fixed installations Part 1:
Design, installation and operation of vessels located above ground
Case Studies
|
|
Isolation |
Documentation
- HS (G) 28 Safety advice for bulk chlorine installations
- HS (G) 30 Storage of anhydrous ammonia under pressure in the UK:
spherical and cylindrical vessels
- Liquefied petroleum gas. IP Model code of safe practice: Part 9
- OIAC. Guidance on Permit to Work systems in the petroleum
industry
Case Studies
|
|
Detection of Releases |
Documentation
- API Std 650 Welded steel tanks for oil storage
- CS1 Industrial use of flammable gas detectors
- Ethylene oxide: CIA Guidelines for bulk handling
- HS (G) 186 The bulk transfer of dangerous liquids and gases
between ship and shore
- IGE SR15 Programmable equipment in safety related applications
Case Studies
|
The Safety Report should show that all foreseeable direct causes
of major accidents have been taken into account in the design of the
installation.
Relevant Technical Measures Documents
Relevant Documentation and Case Studies for Criterion 5.2.1.6
|
Corrosion / erosion |
Documentation
- API 570 Piping inspection code: Inspection, repair, alteration
and rerating of in-service piping systems
- API RP 572 Inspection of pressure vessels
- API Std 620 Design and construction of large, welded,
low-pressure storage tanks
- EEMU 159. Users guide to the maintenance and inspection of above
ground vertical cylindrical steel storage tanks
- HS (G) 40 Safe handling of chlorine from drums and cylinders
- LPGA CoP 1 Bulk LPG storage at fixed installations. Part 4:
Buried / mounded LPG storage vessels
Case Studies
|
|
Extreme weather |
Documentation
- BS6399: Loading for Buildings
- BS 7777: 1993 Part 3 Flat-bottomed, vertical, cylindrical
storage tanks for low temperature service
- CS 18 Storage and handling of ammonium nitrate
- EEMUA 147. Recommendations for the design and construction of
refrigerated liquefied gas storage tanks
- HS (G) 176 The storage of flammable liquid in tanks
- PM 75 Glass reinforced plastic vessels and tanks: Advice to
users
Case Studies
|
|
Impact |
Documentation
- BCGA GN 2 Guidance for the storage of transportable gas
cylinders for industrial use
- EEMUA 147. Recommendations for the design and construction of
refrigerated liquefied gas storage tanks
- PM 75 Glass reinforced plastic vessels and tanks: Advice to
users
Case Studies
|
|
Overpressure |
Documentation
- API RP 520 Sizing, selection, and installation of pressure
relieving devices in refineries
- API RP 521 Guide for the pressure-relieving and depressurising
systems
- API Std 2000 Venting atmospheric and low pressure storage tanks:
Non refrigerated and refrigerated
- BS 2915:1990 Specification for bursting discs and bursting disc
devices
- BS 6759 Safety valves
- CRR 136 Workbook for chemical relief system sizing
- EEMU 184 Guide to the isolation of pressure relieving devices
- HS (G) 176 The storage of flammable liquids in tanks
Case Studies
|
|
Inspection |
Documentation
- API 570 Piping inspection code: Inspection, repair, alteration
and rerating of in-service piping systems
- API RP 572 Inspection of pressure vessels
- ASME Boiler and pressure vessel code: 1998
- BS 7777:1993 Flat bottomed, vertical, cylindrical storage tanks
for low temperature service
- EEMUA 159. Users guide to the maintenance and inspection of
above-ground vertical cylindrical steel storage tanks
- LPGA CoP 1 Bulk LPG storage at fixed installations. Part 3:
Periodic inspection and testing
- LPGA CoP 1 Bulk LPG storage at fixed installations. Part 4:
Buried / mounded LPG storage vessels
- PM 75 Glass reinforced plastic vessels and tanks: Advice to
users
|
|
Fire walls |
Documentation
- LPGA CoP 7 Storage of full and empty LPG cylinders and
cartridges
- NFPA 221 Standard for fire walls and fire barrier walls
|
|
Insulation |
Documentation
- BS 5908:1990 Code of practice for fire precautions in the
chemical and allied industries
- EEMUA 147 Recommendations for the design and construction of
refrigerated liquefied gas storage tanks
- Ethylene oxide: CIA Guidelines for bulk handling
Case Studies
|
|
Vibration |
Documentation
- ASME Boiler and pressure vessel code: 1998
|
|
Human error |
Documentation
- API Std 2000 Venting atmospheric and low pressure storage tanks:
Non refrigerated and refrigerated
- IChemE An engineer's view of human error
- HS (G) 48 Reducing error and influencing behaviour
- HS (G) 65 Successful health and safety management
Case Studies
|
The Safety Report should show how structures important to safety
have been designed to provide adequate integrity.
Relevant Technical Measures Document
Relevant Documentation and Case Studies for Criterion 5.2.1.7
|
Safety of structures |
Documentation
- BS 6399 Loading for buildings
- BS 6651:1999 Code of practice for protection of structures
against lightning
- BS 7777:1993 Part3 Flat bottomed, vertical, cylindrical storage
tanks for low temperature service
- CS 18 Storage and handling of ammonium nitrate
- EEMUA 147. Recommendations for the design and construction of
refrigerated liquefied gas storage tanks
- HS (G) 71 Chemical warehousing: the storage of packaged
dangerous substances
- HS (G) 176 The storage of flammable liquids in tanks
Case Studies
|
The Safety Report should show how the containment structure has
been designed to withstand the loads experienced during normal operation of
the plant and all foreseeable operational extremes during its expected life.
Relevant Technical Measures Documents
Relevant Documentation for Criterion 5.2.1.8
|
Design margins |
Documentation
- API Std 620 Design and construction of large, welded, low
pressure storage tanks
- BS 6759 Safety valves
- HS (G) 176 The storage of flammable liquids in tanks
- IGE SR 14 High pressure gas storage: Part 1 - Above ground
storage vessels
- LPGA CoP 22 LPG piping system design and installation
|
The Safety Report should show that materials of construction used
in the plant are suitable for the application.
Relevant Technical Measures Documents
Relevant Documentation for Criterion 5.2.1.9
|
Materials of construction |
Documentation
- BS 2594:1975 Specification for carbon steel welded horizontal
cylindrical storage tanks
- EEMUA 147. Recommendations for the design and construction of
refrigerated liquefied gas storage tanks
- HS (G) 158 Flame arresters: preventing the spread of fires and
explosions in equipment that contains flammable gases and vapours
- HS (G) 176 The storage of flammable liquids in tanks
- PD 5500: 2003 Specification for unfired fusion welded pressure
vessels
- PM 75 Glass reinforced plastic vessels and tanks: Advice to
users
- SIR 19 Fire and explosion hazards associated with the storage
and handling of hydrogen peroxide
|
The Safety Report should show that adequate safeguards have been
provided to protect the plant against excursions beyond design conditions.
Relevant Technical Measures Documents
Relevant Documentation and Case Studies for Criterion 5.2.1.10
|
Safe operating limits |
Documentation
- HS (G) 93 The assessment of pressure vessels operating at low
temperature
- IGE SR 14 High pressure gas storage: Part 1 - Above ground
storage vessels
- L 122 Safety of Pressure Systems - Pressure Systems Safety
Regulations 2000
Case Studies
|
|
Control Systems |
Documentation
- CRR 166 The management of alarm systems
- EEMUA 160. Safety related instrument systems for the process
industries
- EEMUA 184 Guide to the isolation of pressure relieving devices
- IEC 61508 Functional safety of electrical / electronic/
programmable electronic safety-related systems
Case Studies
|
The Safety Report should describe how safety-related control systems
have been designed to ensure safety and reliability.
Relevant Technical Measures Documents
Relevant Documentation for Criterion 5.2.1.11
|
Safety related control |
Documentation
- IEC 61508 Functional safety of electrical / electronic
programmable electronic safety-related systems
- EEMUA 160. Safety related instrument systems for the process
industries
- IGE SR 15 Programmable equipment in safety related applications
|
The Safety Report should show how design systems, which require human
interaction have been designed to take into account the needs of the
user and be reliable.
Relevant Technical Measures Documents
Relevant Documentation and Case Studies for Criterion 5.2.1.12
|
Human factors |
Documentation
- CRR 166 The management of alarm systems
- IChemE An engineers view of human error
- HS (G) 48 Reducing error and influencing behaviour
- HS (G) 65 Successful health and safety management
Case Studies
|
The Safety Report should describe the systems for identifying
locations where flammable substances could be present and how the equipment
has been designed to take account of the risk.
Relevant Technical Measures Documents
Relevant Documentation and Case Studies for Criterion 5.2.1.13
|
Control of hazardous areas |
Documentation
- BS 6656: 2002 Guide to prevention of inadvertent ignition of
flammable atmospheres by radio-frequency radiation
- BS EN 50014: 1998 Electrical apparatus for potentially explosive
atmospheres. General requirements
- BS EN 60079-10: 2003 Electrical apparatus for explosive gas
atmospheres. Classification of hazardous areas
- HS (G) 103 Safe handling of combustible dusts: precautions
against explosions
- HS (G) 113 Lift trucks in potentially flammable atmospheres
- HS (G) 140 Safe use and handling of flammable liquids
- HS (G) 176 The storage of flammable liquids in tanks
- HS (G) 186 The bulk transfer of dangerous liquids and gases
between ship and shore
- RC 20 Recommendations for the storage and use of flammable
liquids
Case Studies
|
This includes the following Criteria:
Criterion 5.2.2.1
The Safety Report should show that the installations have been
constructed to appropriate standards to prevent major accidents and reduce
loss of containment.
Criterion 5.2.2.2
The Safety Report should describe how the construction of all plant and
systems is assessed and verified against the appropriate standards to ensure
adequate safety.
The Safety Report should show that the installations have been
constructed to appropriate standards to prevent major accidents and reduce
loss of containment.
Relevant Technical Measures Documents
Relevant Documentation for Criterion 5.2.2.1
|
Initial testing of constructed plant |
Documentation
- ASME Boiler and pressure vessel code: 1998
- ASME B 31.3 Process piping: 1999
- BS EN 288 Specification and approval of welded procedures for
metallic materials
- BS 5306 Fire extinguishing installations and equipment on
premises
- BS 6759 Safety valves
- BS 7430: 1998 Code of practice for earthing
- BS 7777: 1993 Flat bottomed, vertical, cylindrical storage tanks
for low temperature service
- CRR 166 The management of alarm systems
- EEMUA 147 Recommendations for the design and construction of
refrigerated liquefied gas storage tanks
- GS 4 Safety in pressure testing
- PD 5500: 2000 Specification for unfired fusion welded pressure
vessels
- PM 75 Glass reinforced plastic vessels and tanks: Advice to
users
|
The Safety Report should describe how the construction of all plant and
systems is assessed and verified against the appropriate standards to ensure
adequate safety.
Relevant Technical Measures Documents
Relevant Documentation and Case Studies for Criterion 5.2.2.2
|
Verification of construction |
Documentation
- CRR 166 The management of alarm systems
- EEMU 160. Safety related instrument systems for the process
industries
- LPGA CoP Bulk LPG storage at fixed installations: Part 3:
Periodic inspection and testing
Case Studies
|
This includes the following Criteria:
The Safety Report should show that safe operating procedures have been
established and are documented for all reasonably foreseeable condition.
Relevant Technical Measures Documents
Relevant Documentation and Case Studies for Criterion 5.2.3.1
|
Safe operating procedures |
Documentation
- BS 5908: 1990 Code of practice for fire precautions in the
chemical and allied industries
- HS (G) 65 Successful health and safety management
Case Studies
|
This includes the following Criteria:
Criterion 5.2.4.1
The Safety Report should show that an appropriate maintenance scheme is
established for plant and systems to prevent major accidents or reduce the
loss of containment in the event of such accidents.
Criterion 5.2.4.2
The Safety Report should show that there are appropriate procedures for
maintenance that take account of any hazardous conditions within the working
environment.
Criterion 5.2.4.3
The Safety Reports should show that systems are in place to ensure that
safety critical plant and systems are examined at appropriate intervals by a
competent person.
Criterion 5.2.4.4
The Safety Report should show that there is a system in place to ensure
the continued safety of the installations based on the results of periodic
examinations and maintenance.
The Safety Report should show that an appropriate maintenance scheme is
established for plant and systems to prevent major accidents or reduce the
loss of containment in the event of such accidents.
Relevant Technical Measures Documents
Relevant Documentation and Case Studies for Criterion 5.2.4.1
|
Maintenance |
Documentation
- HS (G) 28 Safety advice for bulk chlorine installations
- HS (G) 176 The storage of flammable liquids in tanks
- LPGA CoP 1 Bulk storage Tat fixed installations. Part 3:
Periodic inspection and testing
Case Studies
|
|
Proof testing |
Documentation
- ASME Boiler and pressure vessel code: 1998
- EEMUA 147. Recommendations for the design and construction of
refrigerated liquefied gas storage tanks
- IEC 61508 Functional safety of
electrical/electronic/programmable electronic safety related
systems
- LPGA CoP 22 LPG piping system design and installation
Case Studies
|
The Safety Report should show that there are appropriate procedures for
maintenance that take account of any hazardous conditions within the working
environment.
Relevant Technical Measures Documents
Relevant Documentation and Case Studies for Criterion 5.2.4.2
|
Permit to work |
Documentation
- HS (G) 5 Hot work: welding and cutting on plant containing
flammable materials
- HS (G) 64 Assessment of fire hazards from solid materials and
the precautions required for their safe storage and use
- HS (G) 65 Successful health and safety management
- HS (G) 140 Safe use and handling of flammable liquids
- OIAC. Guidance on permit-to-work systems in the petroleum
industry
Case Studies
|
|
Maintenance Procedures |
Documentation
- EEMUA 186. A practitioners handbook - Electrical installation
and maintenance in potentially explosive atmospheres
- GS 4 Safety in pressure testing
- HS (G) 65 Successful health and safety management
- OIAC. The safe isolation of plant and equipment
|
The Safety Reports should show that systems are in place to ensure that
safety critical plant and systems are examined at appropriate intervals by a
competent person.
Relevant Technical Measures Documents
Relevant Documentation for Criterion 5.2.4.3
|
Competent person |
Documentation
- API 570 Piping inspection code: Inspection, repair, alteration
and rerating of in service piping systems
- API RP 572 Inspection of pressure vessels
- ASME Boiler and pressure vessel code: 1998
- BS 7777: 1993 Flat bottomed, vertical, cylindrical storage tanks
for low temperature service
- EEMUA 159. Users' guide to the maintenance and inspection of
above-ground vertical cylindrical steel storage tanks
- LPGA CoP 1 Bulk LPG storage at fixed installations. Part 3:
Periodic inspection and testing
- LPGA CoP 1 Bulk LPG storage at fixed installations. Part 4:
Buried / mounded LPG storage vessels
- PM 75 Glass reinforced plastic vessels and tanks: Advice to
users
|
The Safety Report should show that there is a system in place to ensure
the continued safety of the installations based on the results of periodic
examinations and maintenance.
Relevant Technical Measures Documents
Relevant Documentation and Case Studies for Criterion 5.2.4.4
|
Plant modifications |
Documentation
- HS (G) 28 Safety advice for bulk chlorine installations
- HS (G) 30 Storage of anhydrous ammonia under pressure in the UK:
spherical and cylindrical vessels
- HS (G) 65 Successful health and safety management
- HS (G) 176 The storage of flammable liquids in tanks
Case Studies
|
This includes the following Criteria:
The Safety Report should describe the system in place for ensuring
modifications are adequately conceived, designed, installed and tested.
Relevant Technical Measures Documents
Relevant Documentation for Criterion 5.2.5.1
|
Change procedures |
Documentation
- CIA Guide to Hazard and Operability Studies, CISHEC/8906/1000
- HS (G) 65 Successful health and safety management
|
Page last updated:04/05/2006
