This website uses non-intrusive cookies to improve your user experience. You can visit our cookie privacy page for more information.

Safety report assessment guidance (technical aspects)

Criterion 5.1

The Safety Report should show a clear link between the measures taken and the major accident hazards described.

Relevant Technical Measures Documents

Criterion 5.2

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

Criterion 5.2.1 - Design.

This includes the following Criteria:

Criterion 5.2.1.1 webpage

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

Topic Documents

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

Criterion 5.2.1.2 webpage

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

Topic Documents

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

Criterion 5.2.1.3 webpage

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

Criterion 5.2.1.4 webpage

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

Topic Documents

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

Criterion 5.2.1.5 webpage

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

Topic Documents

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

Criterion 5.2.1.6 webpage

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

Topic Documents

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

Criterion 5.2.1.7 webpage

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

Topic Documents

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

Criterion 5.2.1.8 webpage

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

Topic Documents

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

Criterion 5.2.1.9 webpage

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

Topic Documents

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

Criterion 5.2.1.10 webpage

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

Topic Documents

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

Criterion 5.2.1.11

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

Topic Documents

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

Criterion 5.2.1.12 webpage

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

Topic Documents

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

Criterion 5.2.1.13 webpage

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

Topic Documents

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

5.2.2 - construction.

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.

Criterion 5.2.2.1 webpage

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

Topic Documents

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

Criterion 5.2.2.2 webpage

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

5.2.3 - Operation

This includes the following Criteria:

Criterion 5.2.3.1

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

Topic Documents

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

5.2.4 - Maintenance

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.

Criterion 5.2.4.1 webpage

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

Topic Documents

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

Criterion 5.2.4.2 webpage

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

Topic Documents

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

Criterion 5.2.4.3 webpage

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

Topic Documents

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

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.

Relevant Technical Measures Documents

Relevant Documentation and Case Studies for Criterion 5.2.4.4

Topic Documents

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

5.2.5 - Modification

This includes the following Criteria:

Criterion 5.2.5.1

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

2011-08-12