Finch proposed an approach to conduct Hazard Identification (HAZID) studies on the furnace and to carry out machine risk assessment. The study and risk assessment was conducted collaboratively with the client’s site operations and safety team. Finch were to facilitate and lead the HAZID process and machine risk assessment to systematically identify potential hazards, assess existing functional controls, and determine any additional safeguards required to mitigate residual risks. This approach was to enable the client to strengthen its safety management systems and enhance operational safety, ensuring compliance with regulatory expectations and promoting a safer working environment.
The during
Finch initiated, supervised, authored, reviewed, checked design and inspection records and drawings on a number of comprehensive functional safety systems for a furnace upgrade at the site of a large titanium manufacturer.
The furnace included a number of very dangerous operations using volatile materials.
Initial zoning and access requirements and the volatility properties were provided to Finch. We then chaired a HAZID risk exercise, along with authoring a preliminary machine risk assessment to ISO 12100:2010. A joint machinery risk assessment chaired by Finch resulted.
The HAZID and the ISO 12100 machinery risk assessment identified multiple functional safety requirements in specific areas ranging from oxygen monitoring, ventilation monitoring, movement interlocks, trapped key access through to emergency stops.
For six safety functions, BS EN ISO 13849 was determined to be the most suitable British Standard to follow, and a Performance Level PLd requirement was identified for all.
For one safety function, IEC 61511 was identified as the appropriate standard, a SIL assignment was initiated however this was put on hold to later in the project.
The next step was for Finch to write the safety requirement specifications (SRS) for the six ISO 13849 functions which were submitted them to the manufacturer for comments. Once agreed the SRS’s were issued to a third-party electrical control system and a hydraulic system provider for initial electrical and hydraulic design.
The initial designs were sent to Finch in a SISTEMA format along with the proposed electrical and hydraulic circuits and component datasheets.
An evolving review and re-design process then occurred.
Once we were satisfied with the proposed safety solutions, build and installation were undertaken by the third parties.
During the build and installation, Finch then wrote comprehensive validation documents for each of the safety functions.
The management and documentation aspects of the validation was then undertaken by an independent consultant at Finch, with the site validation checks undertaken by a team consisting of the end user and independent engineers from the third-party equipment suppliers.
Final ‘signed -off’ validation documents were reviewed by Finch.
The result
A comprehensive Process Hazard Analysis process successfully identified key hazards associated with the furnace design and the site’s operations. The upgraded furnace was then successfully put into operation with the customer being very satisfied. The customer now uses the implemented safety process as a model for upgrades to other furnaces. Such an approach was made easier by Finch ensuring the customer was part of the safety process from the start to the end, thereby allowing for skill sets and knowledge transfer.
Through close collaboration between Finch and the client, the process not only validated existing safety controls but also uncovered previously undocumented hazards. This proactive approach enabled the client to implement targeted recommendations that significantly enhanced functional site safety and reduced operational risk. The outcome demonstrates Finch’s commitment to delivering high-quality process safety support and promoting a culture of continuous improvement and hazard awareness in high-risk environments.
