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By David J. LeggettINTRODUCTIONChemical process hazard identificationand risk assessment, at the manufacturingand pilot-plant scale, is a welldefineddiscipline with much open-literaturedocumentation available forguidance.a In essence, the risk assessmentprocess has three stages. First,credible process upsets (accidents) areposited andtheir consequences, andthelikelihood that they will occur, areassessed – risk identification. Second,process and personnel safeguards arereviewed to determine if they are able toprotect workers and assets from theharmcaused by the upset – risk evaluation.Third, the process is modified tolower the risks that could arise from thesynthesis operations, to an acceptablelevel – risk minimization. These modificationsmayincludeenhancements tothe process digital control system, use ofautomated shutdown systems that aredriven by continuous monitoring ofoperational parameters, increasedmonitoring of potentially hazardoussituations, and additions or enhancementsto personal protective equipment(PPE).The degree of risk incurred by anyactivity is a function of the consequence(s) of an upset occurring duringthe activity, and the frequency of itsoccurrence. Frequencies may rangefrom once per month (1 occurrencein 30 days) to once per 3,000 years(approximately 1 in 106 days). In anywell-run organization, includingresearch laboratories, accidents orupsets are, or should be rare events,and the vast majority of faculty andstudents will not experience one duringtheir time working in the laboratory.However, we also know that theprobability of an accident of someseverity in their workplace is not zero.
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