Risk Analyser - User Manual
Contents
1. Intelligent Energy ie Europe Grant agreement no EIE 06 078 S12 447511 Project acronym Gasification Guide Full title of the action Guideline for safe and eco friendly biomass gasification Intelligent Energy Europe IEE Key action ALTENER Deliverable D11 Software Tool Risk Analyzer User Manual Software version April 2008 04 18 DRAFT VERSION Author Friedrich Lettner Peter Haselbacher Helmut Timmerer Markus Seebacher Institute of Thermal Engineering Graz University of Technology Inffeldgasse 25B A 8010 Graz Osterreich Austria www www iwt tugraz at The project is co funded by the European Commission Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide Table of Contents Tapco 0 a g cease eer ee 2 FORO WONG ea a ET ea 3 1 Software tool RISKANAEYSER zung 4 1 1 ODIECIVE and Target groups asked 4 1 2 MSMO ee ee 4 1 3 Required preparation and documents by the user QrOup cccecceseeeeeeeeeeeeeeees 4 2 Installation and system requirements cccccccececeecceeeceeecueceuecaueceeceeeceeeceessueeaeesaees 5 2 1 System FEQUINGITICIS ns een ns 5 22 INSTANALOM Procedure ernst a aeenenaaee teen a 5 2 3 Stan POON AMIS ee ern E E beiisie 6 2 4 UnInStallzans sea E ta Seat legal tanto cts 6 3 General desc DUOMS uses een 6 3 1 Structure and hierarchy of the implemented database 22200220222022n020 6 3 2 Reference des2. Revision 1 0 DRAFT VERSION 22 27 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 7 References 1 2 3 4 9 6 Gasification Guide Guideline for safe and eco friendly biomass gasification project no EIE 06 078 www gasification guide eu in process Steinbach J Antelmann O Lambert M Methoden zur Bewertung des Gefahrenpotentials von verfahrenstechnischen Anlagen Schriftenreihe der Bundesanstalt f r Arbeitssschutz und Arbeitsmedizin Berlin Dortmund 1991 Steen H Handbuch des Explosionsschutzes Wiley VCH Willingdon England 2000 K hnreich K Bock F J Hitzbleck R Kopp H Roller U Woizischke N Ermittlung und Bewertung des Gefahrenpotentials f r Besch ftigte in verfahrenstechnischen Anlagen und Lagereinrichtungen Berlin Dortmund 1998 DIN 6779 10 Kennzeichnungssystematik f r technische Produkte und technische Produktdokumentation Teil 10 Kraftwerke 2007 04 EN 61346 1 Industrial systems installations and equipment and industrial products Structuring principles and reference designations Part 1 Basic Rules 1998 01 14 Revision 1 0 DRAFT VERSION 23 27 Software Tool RISK ANALYZER beta User manual 8 Annex A Default list of events and consequences Table I Default list of events 1 Od O1 A OIN 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 name Leakage gas escape air intake Leakage steam Leakage liquids esc
3. can easily be imported including their properties media parameters from existing settings done for other units Button Import auxiliary media from unit in the unit window Deleting of parameters can be done via the delete parameter button Warning The Delete Button removes the selected data irrecoverable An undo function is not implemented Revision 1 0 DRAFT VERSION 13 27 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 5 Risk analysis 5 1 Risk analysis window Fig 9 shows the risk assessment window Risk assessment has to be applied for each process function here gas scrubbing and transport which is selected in the project tree left In the upper part of the window a list of all parts which belong to the selected function is shown In the lower part of the window lists for events and consequences can be created The default database contains a list of 36 events and 17 preset consequences which can be extended by each user as necessary These two lists can be found in Annex A to this manual Table and Table Il RiskAnalyser Example_Project ProjectTree Example_Project M Components Function Name NEW Code Change operating modes Consequences Consequence _ Abnormal operation conditions i Basic Data 0 Fuel Storage 1 Fuel Feeding and Drying 2 Gasifier 3 Cyclone and Gas Cooling 4 DeDusting 5 Gas Scrubber a Gas Scru
4. ccccccecceececeeeeeeeeceeeseeeeceeeeeeeeseeeseneeaes 27 Revision 1 0 DRAFT VERSION 2 27 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide Foreword The software tool RISK ANALYSER was created in 2007 2008 under the Gasification Guide project which is supported by the Intelligent Energy for Europe programme under contract no EIE 06 078 Biomass gasification is a promising technology which can contribute to the overall EU policy to develop future energy systems which are efficient safe in design and operation as well as environmental friendly and increase the share of renewable energy Gasification technology is near to commercialisation but today large scale introduction is hampered by various reasons Poor awareness and lack of understanding of the Health Safety and environment HSE hazards in the project development planning design construction stage and during operation and maintenance of gasification plants is recognized as a major non technical obstacle The project Guideline for Safe and Eco friendly Biomass Gasification aims to effectively tackle this barrier The objective is to accelerate the market penetration of relatively small scale biomass gasification systems lt 5 MWerue by the development of a Guideline and Software Tool for easy and simple risk assessment of HSE The project homepage can be reached at http www gasification guide eu Legal Disclaimer The sole responsib
5. for which the unit should be defined e g Gas Scrubbing and Transport in the project tree 2 Click New Unit control area of function window bottom left Revision 1 0 DRAFT VERSION 10 27 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 3 Create new unit 4 Assign name and code at least 5 Press Save Data This is shown for the function Gas Scrubbing and Transport in Fig 6 where the following units were defined exemplarily e Quench e Scrubber Tank e Packing material e Scrubbing column W RiskAnalyser beta Example_Project l l iol xi ProjectTree Example_Project Unit Fr zn Basic Data Unit Name 1 Quench i 0 Fuel Storage i 1 Fuel Feeding and Drying Code ail i 2 Gasifier Design parameters i 3 Cyclone and Gas Cooling 4 DeDusting Import parameters from unit Add design parameter Delete design parameter e a bared Name i i i ee Mame Unit Min Normal Max A Gas Scrubbing and Transport ee ee BET ee dust load 1 Quench pressure 2 Scrubber Tank pressure drop j 3 Packing Material temperature I 4 Scrubbing column ef CO sensor Auxiliary media Overview Risk Assessment Import auxiliary media from unit Countermeasures a g Solid Add Medium Parameter Delete Mediumi Parameter ee h Summary ae Hg Scrubbing Media Circulation H Scrubbing Media Recirculation and H A Scrubbing Media Treatment EJ 6 Gas Con
6. shown for the process unit Gas Scrubber in Fig 5 where the following functions were defined exemplarily e Gas scrubbing and transport e Scrubbing media circulation e Scrubbing media treatment e Scrubbing media recirculation and waste water treatment Again functions must have a name and a code For each function a general description is required as well as a description for the plant operation modes verbally in the respective text fields The operation modes are e Normal mode e Start up e Shut down e Emergency stop RiskAnalyser beta Example_Project ejej ioj x ProjectTree Example_Project isi Basic Data 0 Fuel Storage 1 Fuel Feeding and Drying 2 Gasifier 3 Cyclone and Gas Cooling 4 DeDusting 5 Gas Scrubber amp Gas Scrubbing and Transport d Scrubbing Media Circulation d Scrubbing Media Recirculation an Scrubbing Media Treatment 6 Gas Conditioning and Transport 7 Gas Engine 8 Flare Burn off NEU F Fl H A JE Delete r Function Function name Code Function description M Operating modes Normal mode Start Up Shut Down Emergency stop r Control Create Unit Save Data Fig 5 Definition of functions for a process unit 4 4 Definition of units for each function Every function consists of units i e plant parts The defining procedure is 1 Click on the respective function
7. Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 4 6 Definition of auxiliary media for units The user can define an unlimited number of auxiliary solid liquid and gaseous media i e process streams for each unit plant part and assign parameters to them Any process streams can be added by the user as necessary by pressing the button Add Medium Parameter Fig 8 shows the dialog window for the creation and assignment of auxiliary media for units Streams can be assigned with parameters in the following way 1 Selection of a media from the drop down list 2 Selection of a media parameter in the list 3 By pressing the Add Parameter Button the parameter will be added to the media parameter list in the bottom of the screen hence to the selected media 4 New parameters can be created in the fields to the right description and unit and pressing the lt button will add them to the media parameters list left 5 Alternatively media parameters can be deleted by the button O x Description pressure rr pH alue Ei viscosity kinematic lower heating value LHY viscosity dynamic Pressure density hazardous substance classification Unit Add Parameter Delete Parameter Close 1 5 0 2 5 9 0 PH value temperature u Fig 8 Definition of auxiliary media streams for units plant parts After closing the window the user returns to the unit window Here media parameters
8. ample_Project Jai Basic Data Name of Process unit NEU 0 Fuel Storage 1 Fuel Feeding and Drying Code 2 Gasifier Description of Process unit 3 Cyclone and Gas Cooling 4 DeDusting 5 Gas Scrubber 6 Gas Conditioning and Transport 7 Gas Engine ha 8 Flare Burn off NEU Process units M Process unit Process unit 0 Fuel Storage FS1 1 Fuel Feeding and Drying FFD 2 Gasifier GF1 3 Cyclone and Gas Cooling CGC1 4 DeDusting DD1 r SCR M Control New Function Save Data Delete Fig 4 Example for the definition of process units for a typical gasification plant A selected function can be deleted by the usage of the delete button Warning The Delete Button removes the selected data irrecoverable A undo function is not implemented If the foremost process unit is selected and deleted all sub items and information will be lost 4 3 Definition of functions for each process unit Every process unit is subdivided into functions To define new functions the procedure is 1 Click on the respective process unit for which the function should be defined e g Gas Scrubber in the project tree 2 Click New Function control area of process unit window bottom left Create new function 4 Assign name and code at least Revision 1 0 DRAFT VERSION 9 27 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 5 Press Save Data This is
9. ape Leakage scrubbing agents Leakage solids Temperature too high low Pressure too high low Plant flows too high low Plant fill level too high low Concentration too high low Failure mechanical stress Failure thermal stress Failure corrosion Failure icing Failure ware out Failure blocking Failure sealing Failure welding Failure fitting or flange Hot surfaces Failure electric power supply Failure electric plant steering and control Failure electrical device Failure sensor Revision 1 0 description The term leakages includes the types of unpredictable loss of containment of plant media and plant utilities Plant media could be biomass producer gas scrubbing agent etc Plant utilities are possibly pressurised air cooling agents inertisation media like nitrogen etc Physical chemical parameters gives defined operation conditions of the particular investigated functional group an exceeding or undershooting of this normal operation conditions could principally lead to hazards and should therefore be investigated as for too high or too low Part or functional group failure can have various shape depending on operation conditions or mechanical thermal or chemical stress Thermal conversion plants possess system immanent hot surfaces which have to be analysed due to possible hazards f i gasifier gas engine exhaust gas system etc Failure in electrical installations devices or p
10. bbing and Transport Events Risk Assessment Concentration too high low W Countermeasures yy Summary Scrubbing Media Circulation Scrubbing Media Recirculation and H Scrubbing Media Treatment 6 Gas Conditioning and Transport 7 Gas Engine 8 Flare Burn off Failure Failure Failure Failure Failure Failure Failure Failure Failure blocking corrosion electric plant steering and control electric power supply electrical device fitting or flange icing mechanical stress plant media utility supply and disposal C Danger from electricity C Danger to health C Danger to health irritation of skin mucous me C Danger to health skin burns C Explosion C Failure gas engine Emergency stop _ Failure of automation system C Failure of combustion system xi New Consequence z Failure sealina x _ Failure of flare Emergency gas utilisation New event x Add and Delete Events and Consequences fa a Risk Assessment Even Tamsiaten Tconsemenees Ren S cm UV Result m Save Save Data Frequency Severity please choose frequency I I 1 1 Control Show Edit Frequency Severity Parameters please choose severity Fig 9 The risk assessment window 5 2 Definition of frequency and severity parameters In the lower left part of the risk assessment window you can look at the
11. be added opened or deleted ioi x RiskAnalyser Info You can create select and delete new databases here When you select a database you can create or delete projects and choose the one you want bo work on Databases Available databases New Database i Delete Database Example Project Test Rig TU Graz Example Scrubber TU Graz Create Project Open Project Delete Project Fig 1 Front Screen Database and project management After opening a project here Example Project the basic information of the project and the evaluated gasification plant can be filled in into the window Basic Data Fig 2 Data for manufacturer operator and the plant power and performance are requested Data is saved with the button Save Data Revision 1 0 DRAFT VERSION 7 27 Software Tool RISK ANALYZER beta User manual RiskAnalyser beta Example_Project ProjectTree Example_Project a Basic Data 0 Fuel Storage 1 Fuel Feeding and Drying 2 Gasifier 3 Cyclone and Gas Cooling 4 DeDusting 5 Gas Scrubber 6 Gas Conditioning and Transport 7 Gas Engine 8 Flare Burn off Per HrHeHo o Delete EIE 06 078 Gasification Guide ejej ioi xi r Basic Data Plant manufacturer Company UI Street inffeldgasse City Graz Country Austria Phone 433168737811 sits Fax 4433168737305 Homepage Jwww iwetugrazat Contact Jor Lettner No 25 8 Zip Cod
12. currently used frequency and severity parameters You may also adjust them to your needs These parameters are defined for your whole project and will be used in your RiskMatrix and the final report you create Revision 1 0 DRAFT VERSION 14 27 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 5 3 Definition of events and consequences and risk assessment The user can define an unlimited number of events and consequences with the fields New events and new consequences respectively The A button residing left to the New event New Consequence text field will add the new event consequence to the list the Y will delete a marked event consequence from the list The next step is the combination of all possible events in the respective process function with possible consequences The procedure is indicated in Fig 10 and explained in the following 1 Select the event you want to add by clicking on it 2 Select the consequences you want to add to the event by clicking the checkboxes in the consequences window 3 By pressing the V Button in the Add and Delete Events and Consequences group you add them to the Risk Assessment When the combination is selected blue background it can be evaluated with a risk Selection of a probability slide bar Selection a severity slide bar Save Button a St RiskAnalyser Example_Project a l01 x ProjectTree Example_Project Co
13. d unit is designated in the software tool by a code It is recommended to use a structured designation system according to latest international standardisation for power plants t e IEC 61346 1 Structuring principles and reference designation and the RDS PP reference designation system for power plants respectively 5 6 4 Definition of the process and the gasification plant 4 1 Project selection and management RISK ANALYSER stores all information all projects all default settings etc in one or more database files This file is stored in e g lt ProgramDirectory gt db and is called e g database Any new project will be saved into the selected database given on the starting screen Revision 1 0 DRAFT VERSION 6 27 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide The first screen of RISK ANALYSER allows the management of databases and projects within a database file Fig 1 The procedure is 1 Create delete databases In the background a database will be created or deleted 2 Select and open a database The user has to select the wanted data base via mouse click and opens the database by selecting Open database The different projects maybe different gasification plants within this data base will be shown in the window below Create new project or open or delete an existing project When a data base was activated and open existing project within the data base can
14. ditioning and Transport Add Medium Parameter Delete Medium Parameter a 7 Gas Engine H 8 Flare Burn off Scrubbing water Gaseous Add Mediurn Parameter Delete Medium Parameter me o i oS ProducerGas_afterFabFilter Control 5 Save Data Delete Fig 6 Definition of units for the function Gas Scrubbing and Transport exemplarily Again units must have a name and a code Units can be assigned with design parameters and auxiliary media solid liquid and gaseous Exemplarily these data for unit Quench are shown in Fig 6 as well Design parameter for unit quench e g temperature Min 75 C Normal 90 C Max 120 C Auxiliary media Liquid scrubbing water Gaseous producer gas after fabric filter after process unit de dusting Revision 1 0 DRAFT VERSION 11 27 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 4 5 Definition of design parameters of units The user can define an unlimited number of design parameter for each unit plant part By default there is a list of typical design parameters temperature pressure pressure drop tar and particle load in the producer gas to choose from Any other design parameters can be added by the user as necessary by pressing the button Add design parameter Fig 7 shows the dialog window for the creation and assignment of design parameters The procedure is as follows 1 Creation of a new parameter at the fields
15. e Consequences with acceptable risk 2 3 Cyclone and Gas Cooling Original operating mode Consequences with ALARP risk 2 Consequences with unacceptable risk 1 4 DeDusting 5 Gas Scrubber Gas Scrubbing and Transport 1 Quench Countermeasures 2 Scrubber Tank start Up 3 Packing Material Original Start Up mode m via countermeasures reduced 1 Co Monitoring 4 Scrubbing column CO Sensor a5 Risk Assessment Countermeasures Shut Down yy Summary Original Shut Down mode new d Scrubbing Media Circulation u Scrubbing Media Recirculation and u Scrubbing Media Treatment Emergency stop 6 Gas Conditioning and Transport Original Emergency stop mode 1 7 Gas Engine 8 Flare Burn off EB H A A r New operating modes Normal mode Start Up Shut Down Emergency stop Control Create Report Fig 16 Function Summary Revision 1 0 DRAFT VERSION 20 27 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 6 2 Reporting To generate a PDF report for you function or the whole project click the Create Report button at the bottom left of the summary window A dialog box asks you if you prefer printing a report only for the current function or for the whole project Print Report x y You can select whether you want to print a report For this Function or a ae report For the whole project Complet
16. e e010 Mobile Email friedrich lettner tugraz at Plant name l Test Rig TU Graz Example Scrubber Manufacturer Operator Plant operator Operator Ga tt iOSOSCSCSCS S S Street Inffeldgasse 0 City eza Country u Phone 4433168737811 Fax 433168737305 Homepage Jwwwiwttugrazat Contact Jor Lettner No 25 8 Zip Code e010 Mobile Email friedrich lettner tugraz at M Performance data Thermal power 140 0 kwp Electrical power 20 0 kw Fuel power 300 0 kw volume flow producer gas 180 0 m3 h Heating value producer gas 5 0 Mm Fuel Biomass mass flow 60 0 kggsfh Control New Process unit Fig 2 Basic Data of the project and the gasification plant 4 2 Definition of process units The next step is the definition of process units The procedure is 1 Click Basic Data in the Project Tree Left part of the screen 2 Click New Process Unit in the Control area of basic data window bottom left 3 Create new process unit Each process unit must have a name and a code The code can be taken e g from the piping and instrumentation diagram for example P amp I diagram Revision 1 0 DRAFT VERSION 8 27 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide W Riska nalyser beta ROW Fig 3 New process unit of II xl ProjectTree Ex
17. e Report Cancel Fig 17 Selection dialog for reporting The function report is generated as a pdf document in lt ProgramFolder gt reports with the name Reports_ lt FunctionName gt and consists of the following points e Name e Function description e Original operation modes e Unit descriptions o General description o Design parameters o Auxiliary media with media parameter e all units e Risk Assessment e Events and consequences sorted by events o If countermeasures were applied these are documented and the improvement of the risk before and after is shown see Fig 18 Revision 1 0 DRAFT VERSION 21 27 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide RiskAssessment Event Leakage gas escapelair intake Annotation Consequence Name Danger to health Risk Final Risk Consequence Name Failure of flare Emergency gas utilisation Risk Final Risk Consequence Name Poisoning Risk Countermeassures Name CO monitoring Category technical Description New Risk Final Risk ALARP Fig 18 Reporting of Risk assessment with countermeasures applied If you chose to create a complete report additional to all the function reports the file also includes your project s basic data your process units and the frequency and severity parameters you created It is also located in lt ProgramFolder gt reports with Report lt ProjectName gt as filename
18. e working on and the corresponding countermeasures Revision 1 0 DRAFT VERSION 18 27 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide W Risk Matrix probable improbable unlikely very unlikely 4 D O I y UL extremely unlikely significant severe Severities Fig 15 Risk Matrix containing selected consequence and added countermeassures Revision 1 0 DRAFT VERSION 19 27 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 6 Summary amp Reporting 6 1 Summary for each function Summaries are created on a per function basis When you enter the window first the program checks if you have rated all your consequences and countermeasures and if you considered all you newly created parts in the countermeasures window In the upper part of the window you see your original operating modes the consequences with their risks and a list of all countermeasures you created Again operating modes new after changes through risk analysis can be edited this is done in the lower part of the window RiskAnalyser Example_Project Oj x ProjectTree Example_Project Info ial Basic Data Here you find the function operating modes and the countermeasures from the RiskAssesment Record resulting operating mode changes 1 O Fuel Storage here 1 Fuel Feeding and Drying 2 Gasifier Original operating modes Consequences al Normal mod
19. failure reasons see also event list Danger from electricity includes hazards where electrical installation and their possible malfunctions are involved Biomass conversion plants gasification combustion process solid liquid and or gaseous fuels and have to guarantee a safe utilisation of varying feedstock and under different plant operation states normal operation start up shut down etc The stable operation of the automation system assume a functioning process electric system f i unpredictable failure from plant sensor could lead to an total or part wise failure of the automation system Possible dangers to health and impact on environment are summarised within this rubric Fire and explosion are apart from danger to health or environment consequences with an almost always high severity This type of consequence requires in most of cases counter measures and an extended safety concept for successful risk reduction see risk assessment Functions failure means the occurance of and specific function of the investigated unit or sub unit which leads to fatal errors in the process chain DRAFT VERSION 26 27 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 9 Annex B Examples for Function summary Function Summary Name Gas Scrubbing and Transport C1 Function Description Original operating modes Normal mode Start Up Shut Down Emergency stop RiskAssessment Eve
20. form independent the software will be available for all other operating systems in the future 2 2 Installation procedure RISKANALYSER comes with a multi language self installer setup exe which is shown for Windows in the following RiskAnalyser Setup 2 lol x 2 15 x Choose Install Location ee to the RiskAnalyser Setup Choose the folder in which to install RiskAnalyser gt izar This wizard will guide you through the installation of Setup will install RiskAnalyser in the Following Folder To install in a different Folder click RiskAnalyser Browse and select another folder Click Next to continue It is recommended that you close all other applications before starting Setup This will make it possible to update relevant system files without having to reboot your computer Click Next to continue C ProgrammelRisk nalyser Browse Space required 32 4MB Space available 6 8GB Folder Nullsoft Install System v2 33 gt Cancel lt Back Cancel of sox RiskAnalyser Setup ma ioi Installation Complete Tr N Setup was completed successfully gt Completing the RiskAnalyser Setup Wizard Completed Risk nalyser has been installed on your computer SS Click Finish to close this wizard Extract ver2 properties 100 Extract ver2 script 100 Extract ver6 properties 100 Extract ver script 100 Extract C Programme RiskAnalyser s
21. g Media Circulation Scrubbing Media Recirculation and Scrubbing Media Treatment 6 Gas Conditioning and Transport 7 Gas Engine 8 Flare Burn off m Change Frequency New frequency Severity Result unlikely severe a j I Save T n T 7 Create new component here For technical countermeasure Component Name CO Sensor Code col Greate Gomponent Control E Show Risk Matrix Save Data Delete Fig 13 Setting of countermeasures When you select one consequence or one countermeasure all items which belong to the same consequence or countermeasure are highlighted to show their togetherness Technical countermeasures may involve new units plant parts These units can easily be created at the bottom of the countermeasures window At the end of the risk assessment when you enter the Summary window the user is asked whether the new assigned units have also been considered and evaluated in the risk analysis see Fehler Verweisquelle konnte nicht gefunden werden Unit considered xj N 7 Did you take into account the unit you created as countermeasure 7 Unit CO sensor Sco Fig 14 Question dialog for consideration of new units In the lower left part of the window there is a button called Show Risk Matrix If you press this button another window opens and displays the connection between the consequence you ar
22. ignation function and unit codes 2 zu2220022002200nn nennen 6 4 Definition of the process and the gasification plant 022002200220ennennnenenenenennen 6 4 1 Project selection and MANAGEMENT 2240224022002n0nnnnenonenenenenene nennen nennen nenn 6 4 2 DETINIION OF PLOCESS UNIS cise anne een E E AERES 8 4 3 Definition of functions for each process UNIt cccecceeceseeceeeceeceeeeeeeeeeeeeeeseeseeees 9 4 4 Definition of units for each FUNCTION u02200200002000nnno nenn nano nenn nnnnennnen nennen 10 4 5 Definition of design parameters of units 002200224002n0ennnnnnnenennnnnnenenn nennen 12 4 6 Definition of auxiliary media for units 20022000220nenennnnennnenennnnnnenenen nennen 13 9 RISK ANalySiszkentsiasmensee eet set tO hcl a Peed a RO a eek eS dt 14 5 1 RISK analysis WIM OW 2 ze seele nt 14 5 2 Definition of frequency and Severity parameters cece cecccececeeeceeeeceeeeeeeeeeeeaes 14 5 3 Definition of events and consequences and risk assessment ececerreerreen 15 5 4 COUNTERMEASURES enua A a 17 56 Summary REPONN sereia A 20 6 1 Summary for each function asserere Aa a a 20 6 2 REPOND rerna a E a a Asien 21 F REIC NCO S usna a a aaa 23 8 Annex A Default list of events and consequences cccceccceeeceeeeeeeeeeeeeeeeeteeteeeens 24 9 Annex B Examples for Function summary
23. ility for the content of this report lies with the author It does not necessarily reflect the opinion of the European Communities The European Commission is not responsible for any use that may be made of the information contained therein Whilst every effort has been made to ensure the accuracy of this document the author cannot accept and hereby expressly excludes all or any liability and gives no warranty covenant or undertaking whether express or implied in respect of the fitness for purpose of or any error omission or discrepancy in this document and reliance on contents hereof is entirely at the user s own risk Revision 1 0 DRAFT VERSION 3 27 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 1 Software tool RISK ANALYSER 1 1 Objective and target group The generation of the software tool is part of the Gasification Guide project EIE 06 078 1 with the objective to accelerate the market penetration of relatively small scale biomass gasification systems lt 5 MWeuze for the decentralises energy supply systems based on renewable sources Together with the development of a guideline the software tool facilitates the assessment of health safety and environment HSE issues of small scale biomass gasification plants The target group of the software tool are in the first place operators manufacturers project developers researchers and implementers of biomass gasification plants Since the
24. lant steering and control system could be a initial points for a huge number of possible hazards in fully automated plant concepts Therefore a comprehensive analyse on that topic have to be applied according to the listed points of this rubric DRAFT VERSION EIE 06 078 Gasification Guide 24 27 Software Tool RISK ANALYZER beta User manual name 25 Failure plant media utility supply and disposal 26 Harmful plant media and utilities 27 Transient operation start up 28 Transient operation shut down 29 Transient operation increase plant power load 30 Transient operation emergency shut down 31 Operating error 32 Maintenance 33 Force of nature flooding 34 Force of nature stroke of lightning 35 Force of nature storm thunderstorm 36 Force of nature earthquake Revision 1 0 description The reliable supply with plant medias and plant utilities is necessary for the safe and stable plant operation Failures within the supply chain could lead to transient operation states shut down or failure of safety functions Biomass Gasification plants process different medias and utilities which could be harmful for human health and environment A possible loss of containment see also leakage could directly result in health or environmental impairment Transient plant operation states includes start up shut down and changes of plant power load where grave intervention into the plant control parameter
25. mponents Function lal Basic Data Name 0 Fuel Storage 1 Quench Gas Scrubbing and Transport I 1 Fuel Feeding and Drying 2 Scrubber Tank 2 Gasifier 3 Packing Material Code 3 Cyclone and Gas Cooling 4 Scrubbing column sc 4 DeDusti CO Sensor eDusting Change operating modes 5 Gas Scrubber Gas Scrubbing and Transport 1 Quench 2 Scrubber Tank 3 Packing Material 1 Consequences Consequence Concentration too high low C Abnormal operation conditions Failure blocking C Danger from electricity 4 Scrubbing column Failure corrosion C Danger to health CO Sensor Failure electric plant steering and control C Danger to health irritation of skin mucous me gt Risk Assessment Failure electric power supply O Danger to health skin burns Failure electrical device OD Explosion WU Countermeasures f Fr i Failure fitting or flange gt Summary a er U Failure gas engine Emergency stop 2 NEW ns ee N E oe New C a4 u Scrubbing Media Circulation aid hil Deren u Scrubbing Media Recirculation and H Scrubbing Media Treatment Add and Delete Events and Consequences 6 Gas Conditioning and Transport 7 Gas Engine 8 Flare Burn off Risk Assessment a ee ee a a ee TT Leak age sc crubbing agents l Mec hanic Failure Leakage gas escape air intake Danger to health Leakage gas escape air in
26. nt Leakage gas escapelair intake Annotation Consequence Name Danger to health Risk Final Risk Consequence Name Failure of flare Emergency gas utilisation Risk Final Risk Co nsequence Name Poisoning Risk Countermeassures Name CO monitoring Category technical Description New Risk Final Risk ALARP Revision 1 0 DRAFT VERSION 27 27
27. risk assessment should be done in team work since creativity is enhanced and oversight of possible hazards can be reduced Prior to starting the software aided risk assessment the following points should be prepared e plant data process schemes piping and instrumentation diagram P amp I plant part reference designation codes apparatuses design etc e predefined plant operation modes knowledge about start up shut down and normal operation mode process control strategies e desired operation conditions temperature pressure flows and expected gas compositions e machinery lists details construction drawings e mass and energy balances process stream information composition and pollutant load Revision 1 0 DRAFT VERSION 4 27 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide The above process information should reasonable be fed into the software by a single person before starting the risk assessment by the team 2 Installation and system requirements 2 1 System requirements The software RISK ANALYSER is programmed for the Java runtime environment Java has to be installed in order to run RISK ANALYSER The system requirements are e Intel Pentium Ill or equivalent processor e Microsoft Windows Vista Windows XP or Tablet PC Edition Microsoft Windows 2000 512 MB of RAM e Java runtime environment download Java from http www java com en download Since Java is plat
28. s applied by the operator or automatic routines take place Operating error are frequent reasons for hazardous consequences within plant operation so the plant concept should therefore be analysed on such possibilities and further improvement to prevent maloperation process automation technical precaution fail safe Forces of nature have generally to be considered and focuses on the reliability of the process chain under such environmental influences DRAFT VERSION EIE 06 078 Gasification Guide 25 27 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide Table Il Default list of consequences name 1 Abnormal operation conditions 2 Mechanic failure 3 Danger from electricity 4 Failure gas engine Emergency stop 5 Failure of combustion system 6 Failure of flare Emergency gas utilisation 7 Failure of automation system 8 Danger to health 9 Danger to health skin burns 10 Danger to health irritation of skin mucous membrane 11 Noise pollution ototoxic noise 12 Immission exhaust flue gas and smell odour 13 Poisoning 14 Smouldering fire 15 Fire 16 Explosion 17 Failure of function 18 others Revision 1 0 description Abnormal operation conditions are typically described by exceeding undershooting of normal operation conditions and physical chemical media properties and can have various reason This term contains various types of possible failure and
29. software is created generally open in order to be used for any gasification technology and process chain compare with the technology description in the guideline also generated in this project it can moreover also be used for other processes than biomass gasification 1 2 Method From literature there are many possible approaches regarding risk assessment procedures available 2 4 The substantial differences between these methods often lie in the basic approach and the degree of exactness of the reachable results Biomass gasification in small and medium scale systems is partly a unique technology where no explicit techniques and no guidance for the conduction of risk assessment are available This software provides a recommended risk assessment procedure which is practicable and sufficient for the application in biomass gasification plants The chosen method bases on a HAZOP study and is enlarged by additional features which are demanded by the application in biomass gasification plants The method for the risk assessment which is implemented in this software tool is described in detail in other reports of the project and in the draft guideline as well as in the final guideline later on 1 3 Required preparation and documents by the user group Risk identification and assessment is a very extensive work where one needs to be aware of the process its behaviour and the risk assessment methodology itself A general suggestion is that
30. take Poisoning UNACCEPTABLE UW ALARP Leakage gas escape air intake Failure of flare Em Leakage gas escape air intake Failure gas engine j AARP UW Frequency Severity Result extremely unlikely minor Sa aE Control 2 Show Edit Frequency Severity Parameters Save Data Delete Fig 10 Definition of events and consequences Revision 1 0 DRAFT VERSION 15 27 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide According to the combination of probability i e frequency and severity a risk is associated to each pair of event and consequence The risk can be ok alarp or unacceptable Alarp stands for as low as reasonable possible The implemented risk matrix is shown in Fig 11 Unacceptable risks have to be removed by a countermeasure Other risks may also be lowered by counter measures lf a counter measure will be set the shield symbol has to be activated in the CM y n column For unacceptable risks this is activated obligatory As long as there are unacceptable risks within a process function no summary can be created frequent probable Cc D gt casual oO 2 tL imaginable improbable unthinkable inessential marginally Critical disastrous Effects Severity acceptable region ALARP region As Low As Reasonably Practicable Region unacceptable region Fig 11 Risk matrix of frequenc
31. termeasures can be taken in the window Countermeasures The procedure of setting countermeasures is shown in the following 1 Selection of the event consequence 2 Creation of the countermeasure a Name text field b Selection of a category organizational technical constructive process control strategy c Add d Changing of the probability or the severity lowering due to the new countermeasure Revision 1 0 DRAFT VERSION 17 27 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide RiskAnalyser Example_Project 10 x ProjectTree Example_Project Info I ial Basic Data To create new Countermeasure First choose an Event with it s associated Consequence Then you can define and edit new countermeasures For technical 0 Fuel Storage countermeassures you have to define a new component too 1 Fuel Feeding and Drying Events 2 Gasifier era event Annotation T a Resk Leakage gas escape air intake Poisoning TODE Leakage gas escape air intake Failure gas engine Emergency ALARP 5 Gas Scrubber A Gy Gas Scrubbing and Transport 1 Quench 2 Scrubber Tank 3 Packing Material 4 Scrubbing column i r Create countermeasures CO Sensor en H Yv Risk Assessment Name Category WU Countermeasures gt Summary Event Name Category Annotation Resuk amp NEW Leakage gas es Co Monitoring technical d Scrubbin
32. to the right e g Description Water content producer gas and Unit vol H2O_dry basis Pressing create new design parameters will add the new parameter to the list of default design parameters at the left 2 Selection of a design parameter in the list By pressing the Add Button the parameter will be added to the Unit window 4 Apply Min Norm Max values to your parameter Sg Design parameters can easily be imported from existing settings done for other units Button Import parameter from unit in the unit window Deleting of parameters can be done via the delete button Warning The Delete Button removes the selected data irrecoverable A undo function is not implemented W Design parameters l m x Peas Pelee a concentration of organic compounds mg L Description concentration of organic compounds mg l dust load ppm rn water content producer gas dust load ppm dust load mgin n Unit mass Flow m2 nth mass Flow kai valt H2O_ dry basis pressure hPa pressure bar Create new design parameter pressure drop Pa pressure drop mbar temperature oT Delete design parameter temperature k temperature C water content Soy dryvbasis Add design parameter to unit Add Close Here you can add design parameters to your unit create new parameters and delete them Fig 7 Definition of design parameters for units plant parts Revision 1 0 DRAFT VERSION 12 27 Software
33. wt win32 3347 dll 100 Output folder C Programme RiskAnalyser Created uninstaller C Programme Risk4nalyser Uninstall exe Output Folder C Dokumente und Einstellungen haselbacher Startmen Programme Create shortcut C Dokumente und Einstellungen haselbacher Startmen Programm Create shortcut C Dokumente und Einstellungen haselbacher Startmen Programm Output folder C ProgrammelRiskAnalyser Completed i Nullsoft Install System v2 33 Revision 1 0 DRAFT VERSION 5 27 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide 2 3 Start Programme The programme Risk Analyser can be started via Start Programs RiskAnalyser 2 4 Uninstall The uninstaller can be reached via Start Programs Uninstall RiskAnalyser 3 General descriptions 3 1 Structure and hierarchy of the implemented database During the definition of the process and the gasification plant the following hierarchy has to be used 1 Process units top 2 Functions of a process unit cu 3 Units needed to fulfil a function and so belonging to the function For better clarity the whole process has to be divided into process units e g gasifier or gas scrubbing Every process units is subdivided into functions e g cooling of the gas Subsequently units i e plant parts are assigned for each function 3 2 Reference designation function and unit codes Each process function an
34. y vs severity During risk assessment changes in the plant operation may be necessary These adoption can be described in the Change operation modes window see Fig 12 which can be accessed from the risk assessment window On the left side you will find your original operating modes On the right side you can define new operating modes If you want to copy one original mode to the right side click into the mode and press the Copy button Revision 1 0 DRAFT VERSION 16 27 Software Tool RISK ANALYZER beta User manual EIE 06 078 Gasification Guide W Change operating modes z ioj x The original operating modes are on the left side On the right side you can describe changed operating modes IF you want to copy data From the left ta the right side select a textfield an push the copy button Original operating modes New operating modes Normal mode Normal mode Original operating mode Start Up Start Up Original Start Up mode Shut Down Shut Down Original Shut Down mode Emergency stop Emergency stop Original Emergency stop mode Save or copy operating modes Save Copy Close Fig 12 Change operation modes window Changes in the operation mode will be part of the documentation of the risk analysis which will be generated at the summary window project tree for each process function 5 4 Countermeasures For all pairs of events and consequences that were assigned for coun
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