process safety management of plant operations · process safety management process safety...

01/02/05

Property of William J. Tortoriello 1

01/02/05 Property of William J. Tortoriello

Process Safety Management Process Safety Management of Plant Operations of Plant Operations

Element # 2Element # 2Process KnowledgeProcess Knowledge

&&DocumentationDocumentation

01/02/05



Element #2 Element #2 -- Process Process Knowledge & DocumentationKnowledge & Documentation

!! Capturing process knowledge is the Capturing process knowledge is the foundation of a PSM program foundation of a PSM program

!! Formal procedures should be established Formal procedures should be established for maintaining & making available this for maintaining & making available this information in the safety department or information in the safety department or process libraries process libraries

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Why is Process Knowledge & Why is Process Knowledge & Documentation Important?Documentation Important?

!! Original design parameters maintain Original design parameters maintain process integrity over timeprocess integrity over time

!! Rationale for key design decisions can be Rationale for key design decisions can be used for future projects & modificationsused for future projects & modifications

!! Understanding why the process is Understanding why the process is operated & run a certain wayoperated & run a certain way

!! Provides a baseline for reviewing process Provides a baseline for reviewing process changeschanges

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Why is Process Knowledge & Why is Process Knowledge & Documentation Important?Documentation Important?

!! Recording incidents’ causes & corrective Recording incidents’ causes & corrective actions, nuances, abnormalities for future actions, nuances, abnormalities for future referencereference

!! Protecting the company against unjustified Protecting the company against unjustified claims of negligenceclaims of negligence

!! Retaining research & development Retaining research & development information on process chemistry & information on process chemistry & hazardshazards

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7 Process Knowledge & 7 Process Knowledge & Documentation ComponentsDocumentation Components

!! Chemical & occupational health hazardsChemical & occupational health hazards!! Process definition & design criteriaProcess definition & design criteria!! Process & equipment designProcess & equipment design!! Protective systemsProtective systems!! Normal & upset conditions (SOPs)Normal & upset conditions (SOPs)!! Process risk & management decisionsProcess risk & management decisions!! Company memoryCompany memory

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Process Safety ManagementProcess Safety Management

The OSHA PSM standard requires the development of documentation pertaining to:

Process Chemical Hazards

Process Technology

Process Equipment

Process Safety Information

Complete and accurate information concerning process chemicals, process technology and process equipment is essential to an effective PSM Program and represents the 3 components required by the OSHA PSM Standard. Compiling and maintaining this information requires the efforts of various groups. The compiled information is an important resource to many users.

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Process Chemical Hazards include:


•Toxicity information•Exposure limits•Physical, reactivity, and corrosivity data•Thermal & chemical stability data•Hazards of mixing and non-compatabilities

Where can you get this information?

The information compiled about a chemical, including process intermediates, needs to be comprehensive enough for an accurate assessment of the fire and explosion characteristics, reactivity hazards, safety and health hazards to workers and the corrosion and erosion effects on the process equipment. A majority of this information can be obtained from a single document.

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Process Safety ManagementProcess Safety ManagementProcess Safety Information

Product/ Company ID

Composition

Process Chemical HazardsAlso include:

PEL, physical, reactivity and corrosivity inf., thermal/chemical stability data, first aid, fire fighting, handling & storage

MSDS Resources:

MSDS Binders (Factory, M&I, PH, HVAC, etc..), Central Safety & IH Home Page, various Internet sites, Site Safety & IH Department

The primary source of information pertaining to the hazards of chemicals, including toxicity, permissible exposure limits (PEL), physical data and reactivity is the Material Safety Data Sheet (MSDS). MSDSs should be available in all areas where particular chemicals are used and in the site safety department. All employees are required to have initial Hazard Communications training for all processes run in their area and then every time a new material is introduced into their workplace. The OSHA Hazard Communication (HAZCOM) standard can be found in 29 CFR 1910.1200.

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Process technology information includes:


•Block/process flow diagrams

•Process chemistry

•Max inventories

•Safe operating limits

•Consequences of process deviations

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Process Safety ManagementProcess Safety ManagementProcess Safety Information -

Process Technology

BLENDER

M

SeedCrudeL-759,274

L-759,274PURE STEP

VAC

SolventDisposal

L-759,274 Pure

Ethyl actete

Co-mill

ST-101000 gal

GL

CR-301500 gal

GL

TA-33200 gal

SS

TA-121000 gal

GL

Ethyl acetateF15

PROMAN

Ethyl actete

IPA fromdrums

IPA

10µm

n-Heptanen-Heptane

O

NH

O

F

CF3

CF3

N

N

NH

ON

+NaBH(OAc)3

O

N

O

F

CF3

CF3

N

N

NH

N

L-759,274

Process Chemistry & Inventories

Process Flow Diagram

The Technical Operations Dept

Develops and retains this information

Material & Energy Balances

The technology employed in any given process can vary significantly. Block flow and process flow diagrams are simple tools to summarize the major features of a process and make them more readily understood. In most instances only the chemicals and the equipment are identified in block flow diagrams while more details, such as, quantities, temperatures, and flow rates are indicated on process flow diagrams. The reaction chemistry must be fully understood in order to ensure overall process safety. That includes desired as well as undesired chemical reactions. To safely make a product of high quality and purity requires specific materials to be contacted in specific amounts and can require heat input or removal before and during chemical reactions. To ensure this is done safely, Technical Operations Departments or equivalents develop this key PSI and maintain it in a Process Safety Library.

01/02/05




-Process Technology

Process Safety Lab (PSL) personnel use various screening tools to establish process safe operating limits and the consequences of exceeding those limits. They also employ leading edge technology to determine secondary vent sizing (rupture disk), dust ignition/explosion properties, and heat/gas generation during desired and undesired reactions.

Enhanced Adiabatic Calorimeter

Differential Scanning Calorimeter

RC-1 Reaction Calorimeter

20L Sphere -Dust Explosivity

Thermal analysis identifies exothermic activity outside the normal process range, establishes the exothermic onset temperature, quantifies the magnitude of the exotherm, determines the rate of the exotherm.Determining safe operating limits & the consequences of exceeding them (process deviations) is the responsibility of the Process Safety Laboratory (PSL). Some companies have PSLs or contract the service out. Simply put, this group investigates a myriad of upset scenarios, such as, overheating a material, inadvertent mixing of noncompatible ingredients, dropping material that may be sensitive to physical shock & what happens when a spark ignites dry material that is suspended in air. The results of these investigations go into designing and maintaining safer processes. The Process Safety Data Central File, maintained by the PSL, contains this information in the form of Thermal Analysis (TA), Accelerating Rate Calorimetry (ARC), Reaction Calorimetry (RC1) & Dust Explosivity Testing. PSL will develop, interpret and apply this information to ensure a safe process design.

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Process equipment information includes:Process Safety Information

•Piping & Instrumentation Diagrams (P&ID’s)

•Materials of construction & electrical classifications

•Relief system design and design basis

•Ventilation system design

•Safety systems (e.g., interlocks, detection systems, etc.)

•Design codes & standards employed

•Material & energy balances

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Process Safety ManagementProcess Safety ManagementProcess Safety Information -

Process Equipment

Safety Initiatives

CAD (Computer Aided Design) Group

The Safety Initiatives Group develops relief system (PSV & rupture disk) design/basis information. PSL information is often times critical to this effort.

The Doc Center contains critical process equipment information such as equipment files, vendor catalogues, PSV design/sizing files, design codes & standards, project BODs, PM/PDM documentation, validation files, and access to hard copy P&IDs.

The CAD Group creates and maintains the sites drawing library, including P&IDs, electrical classification drawings, and underground utility drawings.

On-Line Doc Center

Safety and Engineering Groups use process information (chemistry, Inventories, etc.) and equipment design information (equipment size, construction and configuration relative to other equipment) to determine the size and type of safety relief valves required to protect equipment and facilities from over pressure events. Piping & Instrumentation Diagrams (P&IDs) are crucial tools used in hazard analysis, incident investigations, engineering projects, management of process and equipment changes, mechanical setups of chemical processes as well as many other applications. The Computer Aided Design (CAD) Group is charged with developing and maintaining these electronic and hard copy documents. In addition to P&IDs, the CAD group also maintains many other drawing resources including electrical classification drawings, equipment layouts, and ventilation system drawings. Sometimes these are available through on-line Doc Centers. Critical to the efforts of maintaining accurate and accessible process equipment information is a Documentation Center. Most process equipment information is maintained in this office and includes, for example, equipment files (e.g., design, installation, purchasing information), vendor catalogs, relief system (safety valves) design/sizing files, design codes and standards (company and industry), basis of design (BODs), for equipment and facilities, preventive maintenance (PMs) and predictive maintenance (PdM) documentation and validation files. Basically one-stop shopping can and should be available at the Doc Center.

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- Process EquipmentAn accurate P&ID can be a valuable resource for information on process equipment including safety systems (interlocks, detection/suppression systems, etc.) material of construction, ID, and basic design information (MAWP, line size, capacity, manufacturer, model, etc.)

Each manufacturing area also maintains a listing of safety systems specific to each process

Information on safety systems (e.g., process interlocks, detection & suppression systems) can be found through several mechanisms. One source for general safety systems is the P&ID of the equipment being investigated for existing or new safety systems. This requires the ability to identify and interpret symbols on the drawing that correspond to a written description of interlock functionality elsewhere on the drawing. These safety systems are sometimes not process or campaign specific, but rather general processing interlocks. For details on process specific safety system descriptions, factories should maintain these listings, as well as, a description of the measured variables and trip points. Fundamental process equipment information can also be found on P&IDs and includes line sizes, material of construction, design pressures and temperatures, vessel sizes, etc.

01/02/05




Chemical Hazards

TechnologyEquipment

Process Safety

Information

PSM

Process Hazard Analysis

Operating Procedures

Each area involved in generating or maintaining Process Safety Information can provide access and/or further discussion as to how it is developed, used and impacts the Site’s overall Process Safety Management Program.

Upcoming Modules...

Knowing now that PSI relates to chemicals, equipment & technology, subsequent modules will highlight how it is used in other PSM activities. Process Hazard Analysis, for example, will demonstrate the importance of this information to Hazard & Operability (HAZOP) studies.Creating Process Safety Information and ensuring its continued accuracy & availability requires the efforts of many departments. Groups involved in making changes to equipment and facilities that impact PSI need to ensure that the appropriate information is updated. This can be accomplished through the Process Change Procedure or the Safety/EnvironmentalAnalysis of Plant & Equipment Modification. Up-to-date PSI not only strengthens our regulatory compliance position, but also increases the effectiveness and efficiency of related documentation intensive activities, such as, abnormality investigations, cGMP compliance, troubleshooting & process campaign startups (mechanical setups, computer sequencing, etc.).You should be interested in obtaining more information regarding PSI interpretation, availability, application and how it fits into the overall PSM Program. This can be done by contacting your site safety department directly or by participating in site safety committees, safety reviews, safety tours, departmental communications, process specifics training and other safety related training.

process safety management of plant operations · process safety management process safety...

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