Introduction to Process Safety Principles.ppt - SIS …

1 10/21/20111 Introduction to Process Safety principles Dr. Angela E. SummersPresident, SIS-TECH Solutions, LPPresident, SISTECH Solutions, LPAIChE Regional 2011 Process Technology ConferenceYoung Professional (YP) SessionContentsWhat is Process Safety ?Standards and RulesResources for a Young Professional (YP)10/21/20112 What is Process Safety ?Industry Success:Personal Safety is:Illness and injury statistics now dominant has driven down rateClassic worker health and Safety Slips, Trips, and Falls Protective EquipmentHot work permitsIndustrial HygieneIndustrial HygieneWhat is Process Safety ? Process Safety is:Industry success:Major Accident PreventionFires, Explosions, ToxicsAccidental chemical releasesNew or modified standards and practices covering Process Safety , instrumentation and controls, mechanical integrity, operator procedures andUnintended reactionsprocedures, and management is Process Safety ?

2 Process Safety is:Personal Safety is:Major Accident PreventionFires, Explosions, ToxicsAccidental chemical releasesClassic worker health and Safety Slips, Trips, and Falls Protective EquipmentHot work permitsUnintended reactionsHot work permitsIndustrial HygieneProcess Safety - On-shoreFederal AgencyOccupational Safety and Health Administration Occupational Safety and Health Administration (OSHA)Promulgated 1990 Clean Air Act AmendmentsStandardOSHA 1910 119 Process Safety Management (PSM) OSHA Process Safety Management (PSM) of Highly Hazardous Chemicals Applies - now Locations with specific chemicals and quantities10/21/20114 Process Safety Offshore Outer Continental ShelfFederal AgencyUS Bureau of Ocean Energy Management US Bureau of Ocean Energy Management, Regulation and Enforcement (BOEMRE) Ruling - Sept.

3 2010 Workplace Safety Rule on Safety and Environmental Management Systems (SEMS)StandardsStandards API RP 75 30 CFR Part 250, Subpart SApplies - Comply by Nov. 15, 2011 Practical Limitation:This presentation cannot cover all elements of PSM or Impact of PSMP rocess Safety Information OSHA PSMS afety and Environmental InformationAPI RP 75 Safety and Environmental Information -API RP 75 Operating ProceduresHazard AnalysisManagement of ChangePre-Startup Safety ReviewMechanical Integrity Quality Assurance/Mechanical Integrity - API RP 75 Process Safety Information (PSI)Timing - Written prior to hazard analysis and thereafter part of MOCpart of MOCR esource - Process Technology, Equipment, and Chemical Hazard InformationProcess Flow DiagramP&IDsMaterials of ConstructionSafe Operating LimitsRelief SystemThermal and Chemical StabilitySimilar to Safety and Environmental Information within API RP 75 Consequence of DeviationsInterlocks, ESDI nadvertent Mixing10/21/20116 Operating ProceduresTiming - Initially written prior to PSSR and thereafter reviewed and certified annually (and with each MOC)reviewed and certified annually (and with each MOC)

4 Resource - PSI and operating steps for each phase Normal, temporary,emergency operationsStart up (Initial, post turnaround, post unplanned shutdown)Shutdown (Normal and Emergency)Tip - Consider all modes of operations during your work. For petrochemical facilities, less than 10% of the time is spent in transient operations; however, 75% of major accidents occur during non-routine operations Hazard AnalysisTiming - Every 5 years10 years for low priority facilities per API RP 75 10 years for low priority facilities per API RP 75 Simple Description - Qualitative evaluation of hazards by experienced teamProcess HazardsPrevious IncidentsHuman factorsFacility siting (potential Consequence of failure of Various methods (HAZOP, Tip - In practical terms, establishes hazard baseline.))

5 After such, managing change is and their potential impact)Monitoring, Controls, Alarms, Interlocks, ESDFMEA, What-If, LOPA, Fault Tree, etc)10/21/20117 Management of Change (MOC)Timing - Prior to non replacement in kind changeSimple description - Written procedures to manage change to Process , technology, equipment, facilities, procedures, and personnel (RP 75).Technical basisPotential impact on Safety and HealthUpdate PSI and proceduresTip - Managing change is key to safe design and maintaining safe to PSSR andstart upInform and train employees and contractorsTiming and Authorization requirementsPre-start up Safety Review (PSSR)

6 Timing - Prior to Implementation of Significant ChangeSimple description - A Safety review prior to start up by those responsible for operations and maintenanceChange in accordance with specificationsSafety, operating, maintenance, and emergencyprocedures inHazard Analysisrecommendations resolvedemergency procedures in place and adequateresolvedTraining completedPSI currentSafe work practices in place10/21/20118 Mechanical IntegrityTiming - ContinuousSimple descriptionWritten procedures to designPressure vessels, piping systems, pumpsRelief and vent systemsEmergency shutdownsystemsControls, alarms, and interlocksDeficiencies outside limits are correctedSuitability with Process applicationSimple description -Written procedures to design, fabricate, install, test and inspect, monitor, and maintain mechanical intent of critical Process equipmentTip - Mechanical integrity extends beyond preventive maintenance and testing.

7 It is a means of ensuring the on-going performance of critical Safety isn t one departmentit ibilit it s everyone s responsibilityProcess Safety isn t a one-time job or a project it s everyday, all dayProcess Safety isn t paperwork it s a way of thinking and actingyggProcess Safety is a culture; it s a way of doing RP 75, Recommended Practice for Development of a Safety and Environmental Management Program for Off hOtid F iliti 3rdEditiMOffshore Operations and Facilities, 3rdEdition, May 2004, Reaffirmed May 2008 Bridges et. al., How to Efficiently Perform the Hazard Evaluation Required for Non-Routine Modes of Operation (Startup, Shutdown, Online Maintenance), AIChE, GCPS, March 2011 OSHA Process Safety Management (PSM) of Highly Hazardous Chemicals Highly Hazardous ChemicalsOSHA 3132, Process Safety Management, Department of Labor Occupational Safety and Health Administration, 1994 (reprinted)