Our client, a pioneering R&D facility specialising in renewable energy technology, was developing a state-of-the-art pyrolysis process designed to utilise a variety of feedstocks from woods to food waste. The technology promised significant advancements in sustainable energy production, but also presented considerable risks, particularly related to fire and explosion hazards.
Project Summary
Challenge:
The challenge was to help the client understand the risks associated with their pyrolysis process, identify the key control measure improvements and to establish a robust basis of safety. The objective was to identify and document key barriers and control measures to mitigate these risks, thereby ensuring the technology could be safely rolled out to clients after the R&D phase.
Solution: Bow Tie Diagram Analysis
To address the challenge, Finch employed the Bow Tie diagram methodology, a proven tool for risk assessment and management, as covered in this article. This approach allowed us to visually map out the potential causes and consequences of identified hazards and to pinpoint critical control measures.
Steps Taken:
- Hazard Identification:
- Previously we had worked with the client to identify hazards using a combination of the HAZID (pre-design) and HAZOP methodologies.
- Bow Tie Diagram Development:
- Created detailed Bow Tie diagrams for several high-risk scenarios. Each diagram consisted of:
- Top Event: Central event representing the potential fire or explosion hazard.
- Causes: Possible causes leading to the top event, such as feedstock handling errors, equipment failure, or operational mistakes.
- Consequences: Potential outcomes if the top event occurred, including facility damage, personnel injury, and environmental impact.
- Created detailed Bow Tie diagrams for several high-risk scenarios. Each diagram consisted of:
- Barrier Identification:
- Mapped out preventive barriers to stop threats from leading to the top event.
- Mapped out mitigative barriers on the right side to minimise the impact if the top event occurred.
- Control Measures and Improvements:
- Identified existing control measures, such as automatic shutdown systems, gas detectors, and bursting discs.
- Recommended enhancements to current controls and proposed additional measures, including audits, improved training programs, more rigorous maintenance schedules, and upgraded safety equipment.
- Basis of Safety Documentation:
- Compiled a comprehensive document detailing the identified hazards, corresponding Bow Tie diagrams, key barriers, and control measures.
- Provided a clear basis of safety, demonstrating how risks were being managed effectively and how safety investments would enhance overall system integrity.
Outcome:
The Bow Tie analysis provided a clear and easy-to-visualise understanding of the risks and control measures associated with the pyrolysis process. The bow-tie diagram was instrumental in:
- Engaging Senior Management:
- Presented the findings to senior management, illustrating the critical need for investment in enhanced safety measures.
- Successfully demonstrated that the technology could be safely scaled up and rolled out to clients with the proposed safety improvements in place.
- Securing Investment:
- Management approved additional funding for implementing the recommended control measures.
- Ensured that the R&D facility could continue its innovative work with a robust safety framework, providing confidence to stakeholders and clients alike.
Conclusion:
By employing Bow Tie diagram analysis, Finch Consulting enabled the R&D facility to gain a thorough understanding of its risks and establish a strong basis of safety. This not only facilitated safer operations but also secured essential investment, paving the way for the successful commercialisation of their groundbreaking renewable energy technology.
If you need further information or advice, please contact Tristan Pulford: [email protected] : 01530412777
