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Cefic Seminar
Transport Risk
Assessment
October 04, 2013, Brussels
Robert Schmidkunz,
BU Site Services - BL Logistics
Utilities & Waste Management Logistics
Technical Services Site Management
Transport Risk Assessment
Approach in the Evonik Industries AG
Zurich Hazard Analysis (ZHA) – Methodology
The ZHA is a tool to identify risks and find
measures to eliminate the probability of their
occurence and/or the consequences
October 2013 | Cefic Seminar Transport Risk Assessment Page 2
Approach in the Evonik Industries AG
• Basic Logistic Concept
• Map Cargo Flow
• Assessment Checklist
Road/Rail/Sea Transport
• Risk Assessment / Route Survey
• Risk Analysis
• Zurich Hazard Analysis
Transport Risk Assessment
Utilities & Waste Management Logistics
Technical Services Site Management
October 2013 | Cefic Seminar Transport Risk Assessment Page 3
Situation Analysis
• Overview of the complete
transportation process based on
our customer´s data
• Analysis of existing equipment /
infrastructure respective transport
safety and security
• Identifying involved
departments/companies for a
methodical risk assessment
Logistic Concept
Utilities & Waste Management Logistics
Technical Services Site Management
October 2013 | Cefic Seminar Transport Risk Assessment Page 4
Map Cargo Flow, Identify Partners, and Process
Map Cargo Flow
Partner ProcessCargo Movement - if
applicableKnown Details About Provider
Days Cargo
is "At Rest"
at this stage
Transport
Mode
Assess-
ment
Production
Site
Producer of
ProductLoading of Product
Company profile and assignment
of tasks
Manufacturing
Plant
on-site
review
Railway
Company 1
Transportation
Supplier -
Railway
company
Rail transport of Product
in rail tank cars
rail transport A - B
Company profile and assignment
of tasksRail transport
on-site
review
Railway
Company 2
Transportation
Supplier -
Railway
company
Rail transport of Product
in rail tank cars -
Switching and haulage
service within the City of
9
Company profile and assignment
of tasks
Terminal and switching Railroad -
links the railroad net between X
and Y (connecting left and right
side of the Mississippi).
Rail transporton-site
review
Railway
Company 3
Transportation
Supplier -
Railway
company
Rail transport of Product
in rail tank cars
serves Evonik site
Company profile and assignment
of tasksRail transport
on-site
review
Evonik SiteConsignee of
product
Unloading of ProductCompany profile and assignment
of tasks
Manufacturing
Plant
on-site
review
October 2013 | Cefic Seminar Transport Risk Assessment Page 5
Content
• Header Customer, Facility Type, Transport Process, Representatives
• Location and Site Factors (Proximity to Public Areas, Accessability9)
• Handling of Product – Experience, Qualification, Permits (Emergency Plan9)
• Technical Equipment for Product-Handling
(Loading/Unloading, Storage, Tanks, Emergency Procedures spills/leaking9)
• Environmental , Health and Safety Impact
Proximity to water, spill control, Personel Protective Equipment, Site Security)
• Fire Protection
• Rail Transport Assessment (Used Equipment, General Questions, Infrastructure9)
• Road Transport Assessment (Used Equipment, General Questions, Infrastructure9)
• Sea Transport Assessment (Used Equipment, General Questions, Infrastructure9)
Assessment Check List
October 2013 | Cefic Seminar Transport Risk Assessment Page 6
The route survey describes the
transport route and possible
alternatives by road, rail, sea, air and
their combinations.
A detailed check of the possible
transport route and points of transfer
under the aspects of transport mode,
safety, risk analysis and Responsible
Care is conducted.
Route Survey
Utilities & Waste Management Logistics
Technical Services Site Management
October 2013 | Cefic Seminar Transport Risk Assessment Page 7
The route survey is recorded:
• Road Journal
• Photo documentation
• Video recording
Route Survey
Country: Peoples Republic of China, Shanghai
Route from - to: Sinopec to MUSC site, normal route, S223
Date: 18.04.2013
Route
No.
KM
on
road
Distance
from
departure Location
Recom-
mended
speed
Risk
level
Contact with
water
possible
Comments 1. Comments 2.
Communi-
cation
possibleAttach-
ment
Photos N°yes no yes no
0entry gate
SINOPECX start X
0,05 km X heavy road bumps X
0,4 km X crossing below trunk line X
0,7 km X unguarded level crossingturn right, road in desperate
condition X
1,2 km X unguarded level crossing X
1,4 km Xbridge crossing over water and
boardwalkbridge loading max. 20 to X
1,7 km X end of bridge road in desperate condition X
1,9 km X crossing below trunk line X
2,1 km X crossroad with signal lights X
2,6 km 60 km/h X first sign speed limit 60 km/h X
2,8 km 60 km/h X cross-walk X
3,0 km 60 km/h X residential area, shopping malls X
3,1 km 60 km/h X cross-walk, shopping mallduring the further road
courseX
3,8 km 60 km/h X Bridge crossing over water X
4,0 km 60 km/h X big crossroad with signal lights X
4,2 km 60 km/h X Bridge crossing over water X
4,8 km 60 km/h X crossroad with signal lights X
4,9 km 60 km/h Xclose residential area, high-rise
buildingsX
5,0 km 60 km/h X road crossing max. 20 to X
5,6 km 60 km/h X Bridge crossing over water bridge loading max. 20 to X
5,7 km 60 km/h X crossroad with signal lights X
October 2013 | Cefic Seminar Transport Risk Assessment Page 8
Identifying potential risks, based on the results of the route survey
• (Each hazard potential or risk can have one or several causes which may be listed
seperately or as a group. Likewise, each cause can have one or several effects. As
each hazard scenario is developed and entered in the Hazard Catalog/Analysis
Sheet, it must be assessed in terms of its relative severity and probability)
Evaluation of the risks (risk matrix and risk tolerance boundary)
• (The Risk Profile is a grid divided into four Severity Categories and six Probability
Levels, whereby the upper right hand corner of the grid represents the highest
severity and the highest probability. In drawing the „Tolerance Boundary“, a
segmented line across the Risk Profile, the team establishes the border between
tolerable (below the line) and intolerable (above the line) risks.
Reviewing the results
Developing risk improvement actions (reducing/minimizing the observed risks)
• (Improvement actions are devised to eliminate or reduce the risks above the Risk
Tolerance Boundary in decending order, starting with those scenarios representing
the highest level of risk.)
Risk Analysis
October 2013 | Cefic Seminar Transport Risk Assessment Page 9
Transport Risk Assessment
Approach in the Evonik Industries AG
Zurich Hazard Analysis (ZHA) – Methodology
The ZHA is a tool to identify risks and find
measures to eliminate the probability of their
occurence and/or the consequences
October 2013 | Cefic Seminar Transport Risk Assessment Page 10
A customer driven risk
management tool
The objective is to identify, assess
and prioritize risks and to provide risk
transparency and improvement
measures.
With the ZHA we take all key
decisions ourselves:
• determine the gravity of the risks
identified
• decide what level of risk we are
prepared to tolerate
• develop tailor-made risk
improvement measures
Zurich Hazard Analysis (ZHA)
Utilities & Waste Management Logistics
Technical Services Site Management
October 2013 | Cefic Seminar Transport Risk Assessment Page 11
Hazard assessment
ZHA Methodology Overview
Zurich Hazard Analysis (ZHA)
Scope Team
Hazard identification
Probability A-F Severity I-IV
Risk tolerance boundary
Company risk policy
Risk Improvement
Priority Sequenz
Hazard
catalog
Risk
profile
Risk
improvement
October 2013 | Cefic Seminar Transport Risk Assessment Page 12
ZHA Methodology
Zurich Hazard Analysis (ZHA)
Hazardous properties Risks in the analyzed area
Disturbances or failures System failure
Environmental effects Impact at the system
Appliance and operation Inaccurate operation
Life cycle Aging, corrosion
People most knowledgeable about the product, process or
components to be analyzed are selected to participate as
team members
Describe the process or components to be analyzedDefine the Scope
Choose the
Team and
Teamleader
Identify hazards
October 2013 | Cefic Seminar Transport Risk Assessment Page 13
ZHA Methodology
Zurich Hazard Analysis (ZHA)
Improvement actions are devised to eliminate or reduce the
risks above the Tolerance Boundery.
Segmented line drawn across the Risk Profile. The RTB
establishes the border between tolerable and intolerable risks
Risk Assessment Analysis Sheet
Risk matrix, divided into four severity categories and six
probability levels.
Build the Risk
Profile
Set the Risk
Tolerance
Boundary
Develop Risk
Improvement
Actions
October 2013 | Cefic Seminar Transport Risk Assessment Page 14
Severity categories
Zurich Hazard Analysis (ZHA)
Severity
category
Consequences for
individuals or environment
Consequences for the
management or
provision of services
catastrophic
Death by accident/incident
and/or several badly injured
and/or serious
environmentally
contamination
critical
Single death by accident/
incident and/or badly injured
and/or important
environmentally
contamination
Loss of an important
system
marginal
Marginal injuries and/or
important thread of
environment
Serious damage of the
system(s)
negligible Possible, minor injuriesMinor damage of the
system(s)
The risk categorization in the
hazard catalog:
I Catastrophic
II Critical
III Marginal
IV Negligible
October 2013 | Cefic Seminar Transport Risk Assessment Page 15
Probability Level of risk
Zurich Hazard Analysis (ZHA)
Category Definition
frequentWill occur frequently. The risk is allways at
present.
moderateWill occur several times. It is to expect, that the
risk occurs often.
occasionalCan occur several times. It is to expect, that the
risk occurs several times.
remoteCan occur during the life-cycle. It is reasonable,
to calculate the risk appearance.
unlikely
The appearance is unlikely, but possible. It may
be assumed, that the risk will occur only in an
exceptional case.
almost impossibleThe appearance is extremely unlikely. It may be
assumed, that the risk will not occur.
The categories for zhe probability
levels are the following:
A Frequent
B Moderate
C Occasional
D Remote
E Unlikely
F Almost Impossible
October 2013 | Cefic Seminar Transport Risk Assessment Page 16
Extract from the ZHA software
Zurich Hazard Analysis –
supported by software
October 2013 | Cefic Seminar Transport Risk Assessment Page 17
Current risk profile
Risk assessment
Plan of measuresTarget risk profile
Sitemap of the ZHA softwareDefinition severty categories
and probability level of risk
Hazard Analysis Sheet
Zurich Hazard Analysis –
supported by software
October 2013 | Cefic Seminar Transport Risk Assessment Page 18
Risk Matrix
Zurich Hazard Analysis
Page 1 Page 1
A A
B B
9 10 11
C C
5 6 7 8 12 13 14 D 5 6 9 10 11 D
4 1 2 3 E 4 1 2 3 7 8 12
13 14 E
IV III II I IV III II I
K: Category K: Category
I Catastrophic II Critical A Frequent B Moderate C Occasional I Catastrophic II Critical A Frequent B Moderate C Occasional
III Marginal IV Negligible D Remote E Unlikely F Almost
Impossible
III Marginal IV Negligible D Remote E Unlikely F Almost
Impossible
S: Probability LevelS: Probability Level
Severity Severity
Prospective Risk Profile
Project:
Pro
bab
ilit
y
Pro
bab
ilit
y
Company: Evonik Industries Company: Evonik Industries
Evonik Industries Evonik IndustriesCurrent Risk
Projekt:
FF
October 2013 | Cefic Seminar Transport Risk Assessment Page 19
We’re enthusiastic.We’re curious.
We’re reliable.
Site Services 2016
We empower our
customers to grow
worldwide.
October 2013 | Cefic Seminar Transport Risk Assessment Page 20