1、1Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersOperationsOperating ProceduresWritten document that provides the following:The steps needed to perform a taskThe order in which those steps are to be performed (if important)Any unique warnings or cauti

2、ons associated with a particular stepPurpose of Operating Procedures2Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersWhere You Need Operating Procedures Operating procedures should address the following scenarios for the production unit. and where com

3、plexity and/or criticality warrant, the same scenarios as above for individual pieces of equipment - e.g. compressors, reactors, etc)3Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersInitial startupTemporary operationsNormal shutdownEmergency shutdownN

4、ormal operationEmergency operations Startup after turnaround or emergency shutdownWhy Is It Important?Without written operating procedures, a facility can have no assurance that the intended procedures and methods are performed in same manner and same sequence by:each different operatoreach time by

5、same operator 4Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersProcedures must be concise and without ambiguityInformation intended for education on chemistry, general hazards, why tasks are performed in a certain order etc. should be placed in traini

6、ng documentsContent of Procedures5Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersProcedures Are NOT Training DocumentsAll procedures are not of same level of criticality/importanceConsider an airlinerTake-off and Landing Procedures Sequence for Re-St

7、art of In-flight Entertainment SystemGuidelines for Storage of Oversize Passenger Bags Risk Ranking of Procedures 6Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersWhen Procedure is . High consequence of deviation High complexityLow-Moderate consequenc

8、e Low-Moderate complexityNegligible consequence Low complexityTier Procedures by Risk Ranking 7Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersUse .Checklist format. In-hand when performing task. Steps initialled.Written format, but required in-hand w

9、hen performing taskWritten format. Place in procedure manual for reference onlyCertification of Procedures - When8Certification should be done before procedure is used for first timeRecertify after any modification, and/or after an established time periodCopyright 2021 Center for Chemical Process Sa

10、fety of the American Institute of Chemical EngineersCertification of Procedures9Certification should be done by field observation that the procedure can be followed .in the sequence providedwithout need for steps/actions not provided in the procedureCopyright 2021 Center for Chemical Process Safety

11、of the American Institute of Chemical EngineersPort Neal IA - 199410Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersWhat HappenedExplosion in NH4NO3 plant in neutralizer and rundown vessels as a result of acidic conditions and high temperatures (200 p

12、sig steam for sparging)4 Fatalities, 18 injuredRelease of 5700t of NH3 and 25,000gal HNO3Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersContributing CausesLack of written operating proceduresLack of training on new DCS systemNo PHA conductedPoor mech

13、anical integrity programCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersDiscussion QuestionHow is “Correctness “ of a procedure certified in your facility ? Is it adequate ?13Copyright 2021 Center for Chemical Process Safety of the American Institute

14、of Chemical EngineersManage RiskTraining And Performance AssuranceCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical Engineers15Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersOperationsTraining and Performance Ass

15、uranceTraining/Performance AssuranceTrainingInstruction in job and task requirements, methods, and hazards if not done as instructedPerformance Assurance (Certification)The means by which workers demonstrate that they understood and retained the training, and can apply it correctly in real-time job

16、situations16Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersWhy Is It Important?17Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersTraining and Performance Assurance is the only means by which a facility

17、 can be certain that an individual . understands the safe and expected procedure for performing a task. understands the consequences of deviation from the expected procedure. is physically and mentally capable of performing the task in the field consistent with the trainingFeyzin, France - 196618Cop

18、yright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersWhat HappenedMajor explosions and BLEVEs at LPG refinery18 fatalities, 81 injuredRelease occurred when operator was draining water from bottom of a sphereIgnition by automobile on nearby motorwayCopyright 2

19、021 Center for Chemical Process Safety of the American Institute of Chemical EngineersWhat HappenedSamples from bottom of sphere routinely taken so bottom had to be drained prior to samplingBottom of tank had two 2-inch plug valves with a -inch bleed valve betweenDrain line heated by steam tracing b

20、eneath insulation Procedure called for opening valve closest to vessel and then cracking open the bleed valve and adjust drawoff rateOperator opened the farthest valve from tank and then tried to open the closest valve to tank. Discharge occurred after an ice plug blew outOperator tried to shut off

21、flow but was unsuccessfulDidnt use telephone in area because of ignition concerns and didnt drive away but walked 800m to control room Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersContributing CausesThe initial loss of containmentLack of operator t

22、rainingThe Ignition and Inability to Protect the SpheresNo means to control traffic on the motorway (distance to motorway 42m) Poor communication systems between field and control roomDelay of firefighting and insufficient water supplyCopyright 2021 Center for Chemical Process Safety of the American

23、 Institute of Chemical EngineersTraining Requirements Training, with Certification, should be provided to all personnel responsible for operating the facility:Initial training (before operating the process)Refresher training (at least every 3 years. Critical tasks on shorter cycle)As part of the MOC

24、 for a process/equipment modification (when warranted by the complexity of the change)Training and Certification should be documented.22Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersCertification / Performance AssuranceTesting for Retention of Knowl

25、edge and Ability to Correctly Perform a TaskAllow several days between the instruction on a task, and the testing of performance on the taskThe “trainer and the “tester should be different individualsPhysical ability to perform the task, as well as ability to perform the task in real-life plant envi

26、ronment (noise, heat, stress) should also be part of certification criteria23Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical Engineers QuestionsHow do you train employees in your company?What is a “passing grade?How do you document the training?Do you refresh

27、training just before a shut down or start up?How do you get employee feedback?What do you do with it?24Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical Engineers25Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersO

28、perationsSafe Work PracticesSafe Work PracticesSafe work practices help control hazards and manage non-routine workA non-routine activity is any activity that is not fully described in an operating procedureSafe work practices typically control hot work, stored energy (lockout/tag out), opening proc

29、ess vessels or lines, confined space entry, and similar hazardous operations26Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersWhy Is It Important?The infrequency of non-routine work increases risk of error and/or inability to recognize a hazard. These

30、 errors or failure to recognize a hazard can lead to catastrophic events. Piper Alpha (removal of a pressure safety valve for recertification)Nitrogen asphyxiation during confined space entry resulted in 80 fatalities in U.S. from 1992-200227Copyright 2021 Center for Chemical Process Safety of the A

31、merican Institute of Chemical Engineers28Piper Alpha - 1988Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersHot Work PermitFire prevention and protection requirements Line Break PermitWorker exposure and spill/release protectionConfined Space Entry Per

32、mitSuitable atmospheres and collapse protection systemsEnergy/Electrical Lock outLock, Tag, & TryUnexpected presence or release of energy29Safe Work Practices - ExamplesCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersDiscussion QuestionsName the Manag

33、ement Systems that Failed at Piper AlphaWould the Systems Used at Your Facility Have Prevented Piper Alpha? If Yes, How?30Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical Engineers31Copyright 2021 Center for Chemical Process Safety of the American Institute of

34、Chemical EngineersOperationsAsset Integrity and ReliabilityAsset Integrity and ReliabilityThe systematic implementation of activities, such as inspections and tests necessary to ensure equipment will be suitable for its intended application through out its lifeSpecifically, work activities focused o

35、n:Preventing catastrophic release of a hazardous material or sudden release of energy andEnsuring high availability or (dependability) of critical safety or utility systems that prevent or mitigate the effects of these types of events32Copyright 2021 Center for Chemical Process Safety of the America

36、n Institute of Chemical EngineersWhy Is It Important?Designing and maintaining equipment fit for its purpose and functions when needed is of paramount importanceMaintaining containment of hazardous materials and ensuring that safety systems work when needed are two primary responsibilities for any f

37、acility33Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersAsset Integrity and Reliability Written procedures should be developed and implemented to maintain the mechanical integrity of equipment including:Pressure vessels and storage tanksPiping system

38、sRelief and vent systemsEmergency shutdown systemsControls, alarms, sensors, and interlocksPumps34Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersAsset Integrity Programs Asset Integrity Programs should address:Written proceduresTraining for maintenan

39、ce activitiesOverview of process and its hazardsSafety procedures applicable to the employees jobCraft skills Inspection and testingFrequency consistent with recommendations and findingsGenerally accepted good engineering practices/standardsDocumentation of findings and actions taken35Copyright 2021

40、 Center for Chemical Process Safety of the American Institute of Chemical EngineersAsset Integrity Programs Asset Integrity Programs should address:Operating Limits Correcting DeficienciesBefore further useIn a safe and timely manner when steps are taken to assure safe operation until permanent corr

41、ections can be madeQuality Assurance ProgramFabrication, Installation, and spare partssuitable for service36Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersAsset IntegrityA system to assure equipment is suitable for its intended application throughout

42、 its lifeMechanical IntegrityA system to assure that equipment used to process, store, or handle HHCs is designed, constructed, installed and maintained to minimize the risk of releases of such chemicalsReliabilityThe probability that an item will perform as expected (designed) when neededMechanical

43、 Integrity and Reliability are not the same thing and are not necessarily equalReliability is often much more than Mechanical Integrity37Asset Integrity, Mechanical Integrity and ReliabilityCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersWritten mecha

44、nical integrity procedures Inspection and testing in accordance with appropriate codes and standardsPHA and incident investigation findings may require changes in mechanical integrity procedures 38Obligations And ExpectationsCopyright 2021 Center for Chemical Process Safety of the American Institute

45、 of Chemical EngineersDiscussion QuestionsHave you defined your MI “process safety critical equipment?How is maintenance training handled?Have you defined acceptable operating limits for equipment?Do you have a quality program for materials received?39Copyright 2021 Center for Chemical Process Safet

46、y of the American Institute of Chemical EngineersDuPont Belle W.Va., 23 Jan 2021BackgroundPhosgene supplied to facility in 1 ton cylindersPhosgene both stored and connected to process from a semi enclosed shed Used as raw material in manufacture of 5 isocyanurate intermediates40Phosgene Shed41What H

47、appenedPhosgene flex transfer hose connected to partially filled, but not in service 1 ton cylinder failed catastrophically1 worker, who happened to be near the site of release, was exposed to the phosgene and subsequently died 42Why it HappenedFlex hose constructed of PTFE lined 304SS which is susc

48、eptible to corrosion Knowledge of better hose material known previously and communicated but not acted uponChangeout and replacement of hoses required on a monthly basis but not followedNon routine operations on day of incident resulted in phosgene left isolated in hose which resulted in thermal exp

49、ansion 43Phosgene Flex Hoses44Hose Changeout Frequency45Asset Integrity Contributing FactorsMaintenance model of SAP used to issue work orders for monthly hose changeoutsIn late 2005 data managing the changeout frequency was modified and WOs no longer issuedNo MOC applied to the changeNo backup prot

50、ection such as critical maintenance checklists or inspection tagsSupervisors relied on maintenance coordinator to remember changeout 46Other Contributing FactorsPHAs deficient corrosion of hoses and liquid expansion in hoses not addressedA 1988 risk analysis identified need for enclosure of shed to

51、minimize primarily off site risk. Options were evaluated but no actions taken. In 2004 a PHA recommended enclosure no action taken Internal Phosgene Committee audit observed hoses had moderate external corrosion but did not provide a recommendation. HTM manual guidance only, not a standard Operators

52、 unaware of hazards of thermal expansion of liquidsNear miss on morning shift the day of incident not addressedDeficiencies in emergency response47CritiqueHave you changed your MMS recently? What steps have you taken to ensure all critical testing is entered successfully into the new system? How rob

53、ust is your MOC process with respect to your MMS?What other safeguards do you employ with respect to ensuring critical safety equipment is maintained, tested and changed out on the designated basis?48Asset Integrity and ReliabilityPrinciplesIdentify equipment and systems that are within the scope of

54、 the asset integrity program and assign inspection, testing, and preventative maintenance (ITPM) taskDevelop and maintain knowledge, skills procedures, and toolsEnsure continued fitness for purposeAnalyze equipment failures and deficienciesAnalyze data49Copyright 2021 Center for Chemical Process Saf

55、ety of the American Institute of Chemical EngineersDiscussion QuestionYour plant has a turnaround every 3 years Process relief valves are tested Management wants to extend the time for turnaround by an additional 18 months This will result in a deviation from the established procedure What do you do

56、 now when this situation develops?What could be done to assure the risk is not unacceptable to management?50Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical Engineers51Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical Engin

57、eersOperationsContractor Safety ManagementContractor (Safety) ManagementSystem of controls to ensureContracted services support both facility operations and the companys process safety and personal safety performance goalsDoes not addressThe procurement of goods and supplies or offsite equipment fab

58、rication functions that are covered by the asset integrity quality assurance functionInvolves workers located closest to process hazards and more routine tasks such as janitorial and ground keeping services52Copyright 2021 Center for Chemical Process Safety of the American Institute of Chemical Engi

59、neersWhy Is It Important?Company can achieve goals:Access specialize expertise that is not continuously or routinely requiredSupplement limited company resources during periods of unusual demandProvide staff increases without the overhead cost of direct hire employees53Companies and contractors shou

60、ld work together to provide a safe workplace that protects the workforce, the community, and the environment, as well as the welfare and interest of the companyCopyright 2021 Center for Chemical Process Safety of the American Institute of Chemical EngineersPiper Alpha54Copyright 2021 Center for Chem