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Process Safety Support for Titanium manufacturer on their Major Accident Hazards

Process Safety Support for Titanium manufacturer on their Major Accident Hazards

A UK-based titanium manufacturer partnered with Finch to conduct a thorough Process Hazard Analysis of their furnace operations, focusing on identifying and mitigating Major Accident Hazards (MAHs) through collaborative HAZOP and HAZID studies. By combining detailed risk assessments, site visits, and a structured approach, Finch helped the client enhance safety controls, reduce risks to As Low As Reasonably Practicable (ALARP), and foster a culture of continuous safety improvement.

Project Summary

Sector

Manufacturing

Capabilities

Process Safety Management

Service

Consulting

The before:

A UK-based titanium manufacturer engaged Finch to support with process hazard analysis of their furnace and furnace operation. The client provided piping and instrumentation diagrams of their furnaces. The client also requested an assessment of three of its key operations which posed potential Major Accident Hazard (MAH) scenarios.

  1. Loading and unloading of crucibles
  2. Cleaning of crucibles
  3. High Voltage (HV) hazards

Finch proposed a hybrid approach to conduct Hazard and Operability (HAZOP) studies on all furnace systems as per the P&IDs they had provided as well as Hazard Identification (HAZID) studies on the key manual operations. The study was conducted collaboratively with the client’s site operations and safety team. Finch were to facilitate and lead the HAZOP and HAZID processes to systematically identify potential hazards, assess existing 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:

As part of the engagement, Finch worked closely with the client’s site team to ensure that all Major Accident Hazards (MAHs) were thoroughly identified, assessed, and formally documented. The Finch team invested additional time to attend the site and observe the operations which posed potential Major Accident Hazards to fully understand the procedures and the risks they posed before the studies began and understand the human factors involved in the process. Through a structured HAZOP and HAZID process, the team evaluated existing control measures and identified additional safeguards where necessary. This collaborative approach ensured that all identified risks were reduced to As Low As Reasonably Practicable (ALARP), aligning with regulatory expectations and reinforcing the site’s commitment to process safety excellence.

Steps Taken:

1. Initial Consultation
Gather relevant information from the team about the processes and equipment which were used on site.

2. Site Visit
Carry out the workshop on site and visit the key hazard areas to help understand the process and capture the key hazards.

3. Risk Assessment:
Hazard identification of all the hazards for different parts of the process.
Safeguards in place to prevent the hazards from occurring.
Other Actions/recommendations to ensure the risks are as low as reasonably practicable (ALARP).

4. Final Reports and HAZOP/HAZID worksheets:
The client received the final reports and HAZOP/HAZID worksheets to support them with carrying out their recommendations.

The result:

A comprehensive Process Hazard Analysis process successfully identified key hazards associated with the furnace design and the site’s operations which posed Major Accident Hazard (MAH) scenarios.

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 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.

For support with your factor's process safety, call 01530 412 777, or email [email protected].

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