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Industry Practice of Process Safety
Contents
• Process Safety (PS)
• Industries practicing PS
• PS applicability in Chemical Engineering profession.
• PS throughout project lifecycle
• Case studies and its relation to your profession.
• Hazard analysis
• Process Safety Management (PSM)
• Inherently Safer Design (ISD)
What is process safety?Keeping medium where it designed to be….
Vessel information
Medium information
Mechanical integrity
Operator training and competency
Operating procedure
Management of Change
What is process safety?
Centre of Chemical Process Safety (CCPS)
Industries & PS
Process Safety vs ProfessionDesign Engineer
Project Engineers
Process Engineers
Operation Engineers
Safety Engineers
Safety Consultants
Academician
Researcher
Fabrication Engineer
Procurement
Inspection Engineers Professional Engineer
Quality Engineer
For a Process Plant to exist…
Concept of process
Process design stage
Engineering stage
Construction Stage
Commissioning stage
Operative stage
Design Engineer
Design Engineer
Design /project Engineer
Project / Process Engineer
Project / Process Engineer
From Plan to Production
Why is it so important for my profession..??
• Naphtha Hydrotreater (NHT) Unit• Rupture of heat exchanger.• Heat Exchanger was severely degraded due to long term cracking damage from High
Temperature Hydrogen Attack (HTHA).
Why is it so important for my profession..??Root causes / contributing factors:• Metallurgical failure:
Fabricated with Carbon steel instead steel alloy which has higher temperature resistance.
Root causes / contributing factors:• Process control failure:
Combined temperature probe, no individual temperature outlet
Fabrication Engineer
Design Engineer
Root causes / contributing factors:• Performance study failure:
Corrosion studies did not recommend HTHA inspection for Heat Exchanger. Studies were performed using design temperature, not operating.
Process Engineer / Consultant Root causes / contributing factors:
• Procedural failure: Leaks observed during start up which was frequent and being treated as ‘normal’ as excepted to cease when reach operating temperature
Operation Engineer
Why is it so important for my profession..??
• Imperial sugar- dust explosion in silo.• 14 killed & 42 injured. • Sugar dust accumulation were noticeable due to poor dust management ( dust
collector, dust cleaning method and continuous spillage and blockage).• Dust in contact with ignition source (overheating of pump bearing).
Why is it so important for my profession..??Root causes / contributing factors:• Poor design:
Poor design of dust managing system allowing of dust escape.
Root causes / contributing factors:• Poor risk assessment:
Conducted by financial risk consultant
Design Engineer
Consultant
Root causes / contributing factors:• Lesson never learned:
Experienced non significant evet of explosion and fire.
Operation Engineer
Root causes / contributing factors:• Failure to address audit findings:
Previous audit identified improvement needed on dust management, no follow up to take action.
Operation Engineer
Ok….how would I know…..??
Hazards that exist
Rules
Risk involved
Codes & Standards
Practices
Experience
Emerging hazards
Is the thoughts that counts
Analyzing hazards and risk
HAZIDHAZOP
QRA
What If
Bow TIe
FMEAFTA
SIL
LOPA
Industries application of risk studies
Process Hazard Analysis (PHA) - HAZOP
HAZOP
HAZOP studies supports acquisition:• Due diligence • Economical value of the asset.
Process Hazard Analysis (PHA) - HAZOPHAZOP Study for Power Plant Construction – Khoakanun Clean Energy Project, Thailand–Detail Design stage.
Process Hazard Analysis (PHA) - HAZOPHAZOP Study for Power Plant Construction – Khoakanun Clean Energy Project, Thailand–Detail Design stage.
The participants:
Process Hazard Analysis (PHA) - HAZOPHAZOP Study for Power Plant Construction – Khoakanun Clean Energy Project, Thailand–Detail Design stage.
HAZOP Assumptions:
• Causes within the node under study.• Failure of primary or secondary protections are not
considered as cause of deviation. • A single check valve considered as acceptable safeguard
against reverse flow.• No double jeopardy – single failure result in deviation of
process condition acceptable.• One train of identical trains will be reviewed instead of both.
Process Hazard Analysis (PHA) - HAZOPHAZOP Study for Power Plant Construction – Khoakanun Clean Energy Project, Thailand–Detail Design stage.
Process Hazard Analysis (PHA) - HAZOP
Recommendations:
• Updating of P&IDs.• Addition of process monitoring probes such as temperature
and pressure.• Identification of process safeguarding system such PALL
(Pressure Alarm Low Low).• Installation of physical protection such as check valves to
prevent gas backflow.• Verification of hydraulic calculation (loading) for the Plant. • Development of operating procedures.
HAZOP Study for Power Plant Construction – Khoakanun Clean Energy Project, Thailand–Detail Design stage.
Process Hazard Analysis (PHA) - HAZOPHAZOP Study for Fatty Alcohol Plant expansion- Conceptual stage- OleochmicalPlant – Port Klang
Process Hazard Analysis (PHA) - HAZOP
Challenges:
• Composition of participants.• Experience and knowledge of participants.• Often design and cost issues takes center stage.• During detailed design stage, conceptual issues
faced.• Disagreement situation between asset owner and
constructor. • Timeline.
Managing process safety
• Continual thoughts, awareness and practices of safety & risk management being put in place in every aspects of ‘Plan to Production’ journey will signify the management of process safety.
Process Safety Management (PSM)
Process Safety Management (PSM)
• PSM standards throughout industries are almost similar.
• Elements can varies (eg: 8 to 14 elements).• But the objectives are same – safe operation. • Many MNC companies takes center stage in playing
championing PSM.
US OSHA Requirement 29 CFR.1910.119
Process Safety Management (PSM)
To elaborate few them….
Chemical / technology / equipment information. Objective:
knowledge and control of operation.
Element that provide guide on performing PHA –
HAZOP/FMEA/SWIFTObjective: Hazard id and control
Process Safety Management (PSM)
To elaborate few them….
Written operating procedures in place providing accurate operating
information of asset. Objective: Knowledge & control of operation.
Requires trg and competency in place for personnel. Objective:
Knowledge & control of operation
Process Safety Management (PSM)
Your journey ….Process Safety Management (PSM)
Engineer Middle Management
Top Management
PSM selected elements Responsibility of PSM elements compliance
PSM as Business KPIWay of achieving HSE
& Business Goal
Inherently Safer Design - ISD
Inherently Safer Design - ISDSeparation of LQ from process area by blast/ firewall
Exhaust release points are routed away from sensitive areas, i.e. crane cabin, helideck
Risers and wellheads are located on BO-D WHRP 70 m away from BO-A CPP
3 x 50% Davit-Launched TEMPSCs
25-men life raft; Four (4) life rafts are provided on the Cellar Deck
Inherent Safety is crucial integral part of the project lifecycle.
Inherently Safer Design - ISD