Consultant- Hydrogen

Location: Philippines

Duration and Schedule:

The assessment is expected to take approximately two (2) months, broken down as follows:

• Preparation and data collection – 1 week
• Site visits and assessment – 2 weeks
• Risk analysis and report drafting – 2 weeks
• Review and final presentation – 1 week

1.0 Background

The hydrogen plant is a critical component of production operations involving the generation and storage of hydrogen gas. Given hydrogen's high flammability and potential for explosive hazards, a comprehensive assessment of the plant's operation and maintenance (O&M) practices is required to identify, evaluate, and mitigate safety risks related to explosion incidents.

This assessment will support compliance with relevant safety standards (e.g., ISO , IEC 60079, NFPA 2, API RP 556, and OSHA Process Safety Management) and ensure the safe, reliable, and sustainable operation of the facility.

2.0 Objectives

The primary objectives of this assessment are to:

• Review current operation and maintenance procedures, systems, and practices of the hydrogen plant.
• Identify potential safety risks and failure modes that could lead to explosion or fire incidents.
• Evaluate the adequacy and effectiveness of existing safety controls, including process safety management, preventive maintenance, and emergency response systems.
• Provide actionable recommendations to mitigate explosion risks and enhance plant safety performance.

3.0 Scope of Work

The assessment will cover the following key areas:

3.1 Process and System Review

• Review hydrogen production and storage systems.
• Examine process flow diagrams (PFDs), piping and instrumentation diagrams (P&IDs), and control logic.
• Identify potential sources of hydrogen leaks or ignition points.

3.2 Operation and Maintenance Practices

• Review O&M procedures for compliance with applicable safety standards.
• Assess operator training, competency, and adherence to standard operating procedures (SOPs).
• Evaluate maintenance scheduling, inspection routines, and record-keeping systems.

3.3 Safety Systems and Controls

• Examine existing explosion prevention and mitigation systems (e.g., ventilation, purging, relief systems).
• Review fire and gas detection systems, alarms, and interlocks.
• Evaluate electrical area classification (ATEX/IECEx compliance).
• Check the integrity of pressure vessels, pipelines, and valves.

3.4 Risk Identification and Analysis

• Perform Hazard Identification (HAZID) and Hazard and Operability Study (HAZOP).
• Assess explosion scenarios (e.g., hydrogen leaks, confined space accumulation, ignition events).
• Quantify risk using qualitative or semi-quantitative methods (e.g., risk matrix, bow-tie analysis).

3.5 Emergency Preparedness and Response

• Review existing emergency shutdown (ESD) procedures and systems.
• Assess fire protection and explosion response measures.
• Evaluate coordination with local emergency services and incident reporting systems.

3.6 Recommendations and Action Plan

• Prioritize identified risks based on severity and likelihood.
• Propose corrective and preventive measures.
• Develop an implementation roadmap with timelines and responsible parties.

4.0 Methodology

• Document Review:
  Review technical manuals, P&IDs, safety data sheets (SDS), inspection reports, and O&M records.
• Site Inspection:
  Conduct walkthroughs to observe equipment condition, housekeeping, and operator practices.
• Interviews:
  Engage plant operators, maintenance personnel, and safety officers.
• Risk Assessment Tools:
  Apply established methodologies such as HAZOP, FMEA, LOPA, or Bow-Tie Analysis.

5.0 Deliverables

• Inception Report – confirming scope, team composition, and work plan.
• Draft Assessment Report – including findings, risk register, and preliminary recommendations.
• Final Report – comprehensive documentation of identified risks, mitigation measures, and improvement plan.
• Management Presentation – summary of key findings and proposed safety actions.

6.0 Team Composition

The assessment team should include experts in:

• Hydrogen process engineering
• Mechanical and electrical maintenance
• Process safety and risk management
• Instrumentation and control systems
• Environmental, Health, and Safety (EHS)

8.0 Reporting and Coordination

The team will report to the designated project manager and coordinate closely with the Operations, Maintenance, and Safety departments. Regular progress meetings will be conducted to ensure alignment and timely feedback.

9.0 References and Standards

• ISO : Gaseous Hydrogen — Refueling Infrastructure
• IEC 60079 Series: Explosive Atmospheres
• NFPA 2: Hydrogen Technologies Code
• API Recommended Practices (e.g., RP 500, RP 556)
• OSHA 29 CFR – Process Safety Management
• ISO 45001: Occupational Health and Safety Management Systems