10/21/2011
Introduction to Process Safety
Principles
Dr. Angela E. Summers
President, SIS
SIS-TECH
TECH Solutions, LP
AIChE Regional 2011 Process Technology Conference
Young Professional (YP) Session
Contents
What is Process Safety?
Standards and Rules
Resources for a Young Professional (YP)
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What is Process Safety?
Industry Success: Personal Safety is:
Illness and injury Classic worker health and
statistics now dominant safety
metric. ‘Slips, Trips, and Falls’
Industry has driven Protective Equipment
down rate Hot work permits
Industrial Hygiene
What is Process Safety?
Process Safety is: Industry success:
New or modified
Major Accident standards and practices
Prevention covering process safety,
Fires, Explosions, Toxics instrumentation and
controls, mechanical
Accidental chemical integrity, operator
releases procedures,
procedures and
Unintended reactions management systems.
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What is Process Safety?
Process Safety is: Personal Safety is:
Major Accident Classic worker health and
Prevention safety
Fires, Explosions, Toxics ‘Slips, Trips, and Falls’
Accidental chemical Protective Equipment
releases Hot work permits
Unintended reactions Industrial Hygiene
Process Safety - On-shore
Federal Agency
– Occupational Safety and Health Administration
(OSHA)
Promulgated – 1990
– Clean Air Act Amendments
Standard
– OSHA 1910
1910.119 Process Safety Management (PSM)
119 “Process
of Highly Hazardous Chemicals”
Applies - now
– Locations with specific chemicals and quantities
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Process Safety – Offshore
– Outer Continental Shelf
Federal Agency
– US Bureau of Ocean Energy Management
Management,
Regulation and Enforcement (BOEMRE)
Ruling - Sept. 2010
– Workplace Safety Rule on Safety and Environmental
Management Systems (SEMS)
Standards
– API RP 75
– 30 CFR Part 250, Subpart S
Applies - Comply by Nov. 15, 2011
Practical Limitation:
This presentation cannot cover all
elements of PSM or SEMS.
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Everyday Impact of PSM
Process Safety Information – OSHA PSM
– Safety and Environmental Information - API RP 75
Operating Procedures
Hazard Analysis
Management of Change
Pre-Startup Safety Review
Mechanical Integrity
– Quality Assurance/Mechanical Integrity - API RP 75
Process Safety Information (PSI)
Timing - Written prior to hazard analysis and thereafter
part of MOC
Resource - Process Technology, Equipment, and
Chemical Hazard Information
Process Flow Diagram P&IDs Materials of Construction
Safe Operating Limits Relief System Thermal and Chemical Stability
Consequence of Deviations Interlocks, ESD Inadvertent Mixing
Similar to Safety and Environmental Information within
API RP 75
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Operating Procedures
Timing - Initially written prior to PSSR and thereafter
reviewed and certified annually (and with each MOC)
Resource - PSI and operating steps for each phase
Normal, temporary, Start up (Initial, post Shutdown (Normal and
emergency operations turnaround, post Emergency)
unplanned shutdown)
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 Analysis
Timing - Every 5 years
– 10 years for low priority facilities per API RP 75
Simple Description - Qualitative evaluation of hazards by
experienced team
Process Hazards Previous Incidents Human factors
Facility siting (potential Consequence of failure of Various methods (HAZOP,
releases and their potential Monitoring, Controls, FMEA, What-If, LOPA,
impact) Alarms, Interlocks, ESD Fault Tree, etc)
Tip - In practical terms, establishes hazard baseline.
After such, managing change is key.
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Management of Change (MOC)
Timing - Prior to non ‘replacement in kind’ change
Simple description - Written procedures to manage
change to process, technology, equipment, facilities,
procedures, and personnel (RP 75).
Technical basis Potential impact on Safety Update PSI and
and Health procedures
Prior to PSSR and Inform and train employees Timing and Authorization
start up and contractors requirements
Tip - Managing change is key to safe design and
maintaining safe operations.
Pre-start up Safety Review (PSSR)
Timing - Prior to Implementation of ‘Significant’ Change
Simple description - A safety review prior to start up by
those responsible for operations and maintenance
Change in accordance Safety, operating, Hazard Analysis
with specifications maintenance, and recommendations
emergency procedures in resolved
place and adequate
Training completed PSI current Safe work practices in
place
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Mechanical Integrity
Timing - Continuous
Simple description - Written procedures to design
design,
fabricate, install, test and inspect, monitor, and maintain
‘mechanical intent’ of critical process equipment
Pressure vessels, piping Relief and vent systems Emergency shutdown
systems, pumps systems
Controls, alarms, and Deficiencies outside limits Suitability with process
interlocks are corrected application
Tip - Mechanical integrity extends beyond preventive
maintenance and testing. It is a means of ensuring the
on-going performance of critical equipment.
Summary
Process safety isn’t one department
– it’ ’ responsibility
it’s everyone’s ibilit
Process safety isn’t a one-time job or a project
– it’s everyday, all day
Process safety isn’t paperwork
y of thinking
– it’s a way g and acting
g
Process safety is a culture; it’s a way of doing
business.
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References
API RP 75, “Recommended Practice for Development of
a Safety and Environmental Management Program for
Off h
Offshore O ti
Operations dF
and iliti ” 3rd Edition,
Facilities,” Editi M
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 1910.119 “Process Safety Management (PSM) of
Highly Hazardous Chemicals”
Chemicals
OSHA 3132, “Process Safety Management,” U.S.
Department of Labor Occupational Safety and Health
Administration, 1994 (reprinted)