ADVANCING PROCESS SAFETY WEBINAR SERIES

2018: Webinar 1 out of 5

Tuesday, February 27th

Agenda

1. Introduction and Purpose – Steve Mason, LyondellBasell Ind.

2. Process Safety Event Collection Sheet – Felicia Miller, Delek and Dan Wilczynski, Marathon Petroleum Company

A. New featuresB. Example reviewC. How to submit to AFPM and API

2. Upcoming Advancing Process Safety Opportunities – Steve Mason, LyondellBasell Ind.

A. ConferencesB. PublicationsC. Webinars

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Purpose• Update participants on recent learnings stemming from AFPM/API Advancing

Process Safety programs

• To ensure consistency in Tier 1 and 2 metrics reporting in order to establish

credibility and validity

• To share learnings regarding the effective implementation of Tier 1-2

lagging/leading metrics

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• Industry Learnings and Outreach including Event Sharing and API RP 754

• Hazard Identification and Practice Sharing

• Site Assessments

• Regional Networks

• Human Reliability: Permit to Work and Fired Heaters

• Mechanical Integrity

Trend Charts for PSE 1 and 2

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2016 Participation

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• Petroleum Refining

• 34 companies representing 101 facilities

• 95% of Refining capacity

• Petrochemical Manufacturing

• 22 companies representing 118 facilities

• Total for RF and PC

• 56 Companies representing sites 219

Process Safety Event

Collection Spreadsheet –

What’s New and Example

Review

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Point of Release – Detail 1 and Detail 2 Addition

Point of Release

Atmospheric tank

Blow er/Fan

Compressor

Cooling Tow er

Filter/Coalescer/Strainer

Fired Boiler

Flare/Relief System

Furnace/f ired heater

Heat exchanger

Instrumentation

Piping system, large bore(>2)

Piping system, small bore(≤2)

Pressure Vessel

Pump

Reactor

Other (describe)

PoR Detail 1

Air Cooler Type

Analyzer

Auxiliary System Leak

Boil over

Casing Leak

Channel Head /

Tubesheet / Gasket Leak

Control valve

Dead leg

Directly to atm

Drum

Expansion joint

Firebox explosion

Fitting leak

Flange / Gasket Leak

Flare liquid carryover /

rainout

Flare pilots out

Flare system leak

Flowmeter

Fuel leak

Head / closure gasket

leak

Hose leak

Housing leak

Insufficient information

Lack of vapor controls

Leak

Level instrument

Open ended line

Other

PoR Detail 1 (cont'd)

Overfill

Packing leak

Piping leak

Piping repair clamp leak

Pressure boundary leak

Pressure instrument

Pressurized storage

Process tube leak

PVC or other non-metallic

Relief valve leak

Roof sinking

Seal leak

Shell and tube leak

Shell leak

Sight glass

Sight flow indicator

Small chemical injection

pump

Steam / water tube leak

Temperature instrument

Threaded fitting leak

Tower

Toxic release

Tube leak

Tubing leak

Valve

Vapor / gas blow thru

PoR Detail 22" or less

Body failure

Braided metal

Chemical hose

Copper tubing

Crack / hole

During blind installation /

removal

Engineered clamp

Fitting body leak

Fitting / connection

Flange face damage

Gasket

Gasket failed

Glass failure

Greater than 2" diameter

Insufficient information

Leak at fitting /

Leak in hose

Loose bolts

Loose fitting

Plastic tubing

SS tubing

Threaded fitting leak

Utility hose

Valve body leak

Valve leak thru

Valve left open

Valve packing leak

Wrong gasket

Modifications Associated with Causal Factors

3 Max

Details for Each Causal Factor

QC Check

Importing API RP 754 Data to Event Sharing

• AFPM has implemented a process where companies can

request that their API RP 754 submittals be imported into

their Event Sharing queue.

• Process

– Company identifies which events they want imported to

event sharing when they submit their API RP 754 data

– AFPM performs QAQC in April

– Once final report is published, AFPM will import events

for companies into the company Administrator’s queue

PSE Example Entry

Review – Questions and

Clarifications

Let’s Walk Through an

Example

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PSE 754 Submissions

-AFPM Submissions can be emailed to either

- Toby Palmer (tpalmer@vaultconsulting.com)

- Anna Scherer (ascherer@afpm.org)

-API Submissions can be emailed to

- Alexa Carlson(CarlsonA@api.org)

Both associations have a hard deadline of March 9, 2018

-For questions on API 754 PSE interpretations please email

- Heidi Keller (KellerH@api.org)

Look out for APS Presentations at the following

Meetings!

• AFPM Annual Meeting – New Orleans, LA – March 11–13

• API / AFPM Spring Operating Practices Symposium – Seattle, WA -

April 18

• Registration Open: http://www.api.org/products-and-

services/events/calendar/2018/springops

• CCPS Global Congress on Process Safety – Orlando, FL – April 22-

25

• AFPM Reliability and Maintenance Conference – San Antonio, TX –

May 19-22

AFPM National Occupational &

Process Safety Conference

• Registration Open

• May 15-16, San Antonio, TX

• All Regions Meeting

• Process and Occupational

Regional Networks

• May 17

• Awards Event

• Evening of May 16

• Registration:

• https://www2.afpm.org/forms/meetin

g/Microsite/NSC18

Walk the Line Workshop

• July 25-26, 2018

• Houston Area, TX

• July 25: 1:00-5:00pm

• Cocktail reception

• July 26: 8:00am-1:30pm

• Registration to Open in April

• Agenda

• General Session Presentation and Panel

• Getting Started

• Breakout Session

• Operational Readiness and Commissioning

• Measuring Success

• WTL Technology

• Sustainability and Ownership

Process Safety Related Documents Coming Soon

AFPM Practices Sharing:

Temporary Leak Repair Checklist and FormThis practice provides a checklist that serves as a template for the review of potential hazards of temporary

repairs that can include installation of clamps, enclosures, overlays, wraps and “Tell-Tale” (T-T) pins,

including the re-tightening and reinjection of sealant in temporary repair enclosures to help prevent loss of

containment events.

Control of Defeat of Safety Critical EquipmentThe purpose of the Control of Defeat work practice is to ensure that the necessary analysis, authorization,

communications and recordkeeping is performed when disabling or impairment of SHE (Safety, Health,

Environment) Critical Devices occurs.

Radio Communications ProtocolThis practice utilizes defined radio communication protocol in an operation that requires close coordination

between field and console operators is important to effective performance and avoidance of unintended

consequences.

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2018 Webinars

• What do the Webinars cover?– Focused Topics

– New Documents Coming from AFPM

– API 754 Queries of Interests

• Planned 2018 Webinars

Date Topics

February 27 PSE Data Collection

April 10

Note: Change

from April 17

to April 10

Integrity Operating Windows – Common Pitfalls and Company Practices

Speakers:

• John Reynolds, Intertek

• Chad Patschke, Ethos MI

• Clay White, P66 (Invited)

• Mike Urzendowski, Valero (Invited)

June 19 HR - Fired Heater; PSE Data Collection Results

September 12 Human Reliability (HR) – Permit to Work

November 13 Best of Regional Networks

How to Access the Safety Portal?

All AFPM Members have access to the AFPM Safety Portal

To see if you are a member:

https://www.afpm.org/membership-directory/

Safety Portal Link:

www.afpm.org/safetyportal/

You will need your AFPM Username and Password to access the Portal. If you have

forgotten it or need to set one up, follow the instructions on the login page.

Note: For Access to Process Safety Metrics, Injury & Illness Metrics, and Event Sharing database, you will

need to get permission from your company’s database administrator. Those individuals are listed in the

bottom right hand corner of the Portal Homepage.

For all questions and information, contact:Lara Swett

Senior Director, Safety Programs

AFPM

202-552-8476

lswett@afpm.org

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