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Introduction To Process Safety Principles

This document provides an introduction to process safety principles. It defines process safety as preventing major accidents related to fires, explosions, toxic releases, and unintended reactions. It discusses key process safety standards from OSHA and BOEMRE. Everyday elements of process safety management systems are also outlined, including process safety information, operating procedures, hazard analysis, management of change, pre-startup safety reviews, and mechanical integrity. The presentation emphasizes that process safety is an ongoing responsibility requiring a safety culture.

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Wafa Habib
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Download as PDF, TXT or read online on Scribd
87 views

Introduction To Process Safety Principles

This document provides an introduction to process safety principles. It defines process safety as preventing major accidents related to fires, explosions, toxic releases, and unintended reactions. It discusses key process safety standards from OSHA and BOEMRE. Everyday elements of process safety management systems are also outlined, including process safety information, operating procedures, hazard analysis, management of change, pre-startup safety reviews, and mechanical integrity. The presentation emphasizes that process safety is an ongoing responsibility requiring a safety culture.

Uploaded by

Wafa Habib
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 9

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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10/21/2011

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.

2
10/21/2011

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

3
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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.

4
10/21/2011

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.
16

8
10/21/2011

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)

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