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Process Safety Engineering 1

PROCESS SAFETY ENGINEERINGBogot D.C. (Colombia)

June 28th

- July 22nd

2011

Course Coordinator: Julio Csar Vargas (COL)

International Invited Lecturers: Nicolai Caicedo (UK)

Neill C. Renton (UK)

Ana Mara Cruz, (Japan, France)

National Invited Lecturers:

Felix Rivera (Consejo Colombiano de Seguridad)

The U. S. Chemical Safety Board (CSB), as a result of the T2 Laboratories accident*, has recommended

that the Accreditation Board for Engineering and Technology (ABET) and the American Institute of

Chemical Engineers (AIChE) work together to add reactive hazards awareness to the B.S. chemical

engineering curriculum [1]. Subsequently, the Safety and Chemical Engineering Education committee

(SACHE a CCPS committee), recommended a broader approach, for example: a) teach the

importance of process safety, b) teach the importance of understanding hazards including toxic,

flammable, and reaction hazards, c) teach how to control and mitigate hazards to prevent accidents,

and d) teach the importance of inherent safety [2].

INTRODUCTION

Since the 1970s there has been a world-wide steady rising trend in losses due to industrial accidents.Continuous development during the last few decades has modified the process operating conditions

in order to gain efficiency of the process. Higher pressures and higher temperatures used in the

industry nowadays mean higher stored energy which results in an increased risk in case of a sudden

release.

It is very important for process engineers to understand how technical safety is formulated and

implemented as a main topic in the prevention and control of potential losses due to operational

conditions and it shapes the direction and activities of the teamwork and the organisation.

It has been recognised that engineering processes must involve safety management systems

throughout all phases of the project, giving emphasis to the concept and design stages as a means of

controlling the safety issues with a higher level of effectiveness.

Moreover the new global challenges, have forced government agencies to introduce new legalrequirements to assess and control industrial risks to people (individuals & society) and to the

environment. At the same time companies want to demonstrate competitive advantages through

social responsibility by the creation of high integrity engineering systems.

In the global context many industries have already designed and implemented safety standards with

the goal of reaching high levels of safety performance. Some of these industries include offshore and

onshore oil and gas production, nuclear power plants, aerospace and process industries amongst

others.

*

U.S. Chemical Safety and Hazard Investigation Board Investigation Report: T2 Laboratories, Inc. RunawayReaction (Four Killed, 32 Injured), REPORT NO. 2008-3-I-FL, September 2009. Available On-line:

http://www.csb.gov/UserFiles/file/T2%20Final%20Report.pdf

[1] Willey R.J., Editorial Process Safety Progress 29 (2010) 1

[2] Louvar J. F. Editorial-Industry Teaches Process Safety in Universities Process Safety Progress 29 (2010) 97


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WHO WILL BENEFITThe aim of this course is to provide tools to a wide array of professionals to develop the concept of

safety engineering through several activities. The course may be convenient for those people who

are interested in working in fields such as Chemical and Petrochemical Engineering, Safety

Engineering, Process Engineering, Mining Engineering, Insurance Industry and Risk Management, aswell as safety co-ordinators, process design engineers, environmental engineers, maintenance co-

ordinators, ARPs assessors, insurance assessors, independent consultants, safety auditors amongst

others.

CORE TOPICSThe aim of this course is to introduce participants to the concepts, theories and frameworks that will

improve their understanding of technical safety and its impact on engineering processes.

The focus of this course is on the nature of using safety concepts as a competitive strategy in the

global context, providing tools to improve the Capital Expenditure (CAPEX), by reducing costs

associated with premium insurances, fines, and shut downs and start-ups due to system failures.

It examines how, in an engineering environment, competitive advantage might be developedthrough the application of technical safety elements that may be exploited in a cost-effective

manner.

Module 1. Safety Concepts and Legislation (16 h)(National lecturers, June 28

thto July 1

st)

Key Features:

Safety Management and National Regulation Safety Management & Legislation Prevention & Emergency Management

Probability Theory Reliability and Maintenance - RAM Probability Failure on Demand PFD Redundancy Concept

Module 2. Safety Critical Elements & Risk Assessment (16h)(Nicolai Caicedo, July 5

thto July 8

th)

The first approach to the safety process concept should be made in early stages of the project.

Concept and design activities in an engineering project are by default the target when safety

principles want to be applied. This is based on the fact that the sooner changes to improve safety are

introduced the cheaper the cost.

The risk assessment process takes into account historical failure data that has been collected for

different elements and systems. Once these have been applied to the current project and analysed,

figures for the expected performance can be generated which will be further compared against base

lines called acceptance criteria.

Key Features:

Basic concepts in safety processes Hazards (Fire, Explosion) Accidents Reliability and Maintenance - RAM F-N Curves


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Human Factors Human Failure The accident causation model

Inherently Safe Design Concept Methods Mitigation

Risk Identification Techniques Preliminary Hazards accidents - PHA HAZOP / HAZID

Risk Analysis Techniques Bow Tie, Fault Tree Analysis, Even Tree Analysis, Safety Integrity Level analysis Quantitative Risk Analysis - QRA

Safety Case Safety Model Safety Culture Accident Case studies

Module 3. Structural Integrity in process engineering environments (16h)(Neill C. Renton, July 12

thto 15

th)

Historical data is usually the quickest way to determine the projects life cycle, although in many

cases it is inappropriate to determine the loss of integrity frequency. If used the appropriateness

[type of structure, geographical location] of the data should be assessed.On the other hand, reliable and comprehensive structural data are an essential requirement for the

structural integrity assessment of an installation during its life cycle as this information will be useful

when determining the total risk associated with the facility and its further impact in term of

incidental risk.

Moreover, reassessments carried out during safety inspections should be able to reflect

deterioration of facilities structural elements in order to quantify reliability and availability of the

assets involved in risk prevention.

Key Features:

Fatigue Failure Corrosion Reliability Predictions Extent of Structural Damage/Failure Remaining Life

Module 4. Major Accident Hazards in Process Plants Identification, Causes &

Consequences (16h)(Ana Mara Cruz, July 18

thto July 22

nd)

Implementation of safety concepts and safety culture into a particular facility does not always avoid

the occurrence of major accidents. Some of these accidents may lead to serious injury to people,

damage to the environment, loss of assets not only close to but also further away from the site ofthe accident.


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The measures to be implemented should respond not only to internal design and a particular

operational mode, where different kinds of failures may be identified but also to the analysis of the

potential consequences to people, property and the environment on site and offsite of a major

chemical accident if one does occur.

Key Features: Heath Safety Environmental Impact Assessment Environmental Hazards Hazardous Area Classification Propagation & Domino Effects

Dispersion and CFD Models PROBIT functions

F&E Prevention & Mitigation Releases

Liquid Gas/Vapour Mitigation Fires Pool Fires Ball Fires Jet Fires

Explosion Detonation Deflagration DDT Dust

LEARNING AIMS AND OUTCOMESThe main aim of the course is to provide engineers with the knowledge, skills and competencies to

understand and develop technical safety in order to assist their processes in the creation and

capture of value as well as to obtain sustainable competitive advantage. Through this process,

engineers will develop an understanding of the impact of applying safety principles during the

development of the project.

Key Learning Aims of the Course

Develop a high level appreciation of issues related to technical safety. Examine critically advanced theoretical frameworks. Integrate the theoretical, conceptual and analytical considerations of technical safety Critically analyse ways in which the operations function contributes to the safety

performance of the process.

Industrial Related Learning outcomes

Formulate and develop coherent strategies that are holistic in nature and internallycongruent in terms of both conceptual and operational requirements.

Carry out independent study and research in the subject areas of the course Enhance ability to find, present and use quantitative & qualitative safety data in suitable

formats by using appropriate techniques and applying IT skills.

Discuss in context the linkage between current theory and practice and be able to organiseappropriate evidence and reasoning to produce a balanced conclusion.

Be able to actively participate in technical discussions related to safety in the process.


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TEACHING AND LEARNING ACTIVITIESThe course tutors will aim to combine lectures with tutorial activities. This environment will provide

opportunities for the participants to understand the course material through case studies to apply

the knowledge acquired in a practical way. The intent is to facilitate interactive class activities, and

discussion regarding the significant role of technical safety in a global context.

SOURCE MATERIALAs well as the handouts for the whole course the attendant is expected to make full use of at least

the following sources.

Core and Recommended Reading Cox. S., (1998) Safety, Reliability and Risk Management, 2nd Ed. Butterworth Heinemann. Lees. F.P, (1996) Loss Prevention in Process Industries. 2nd Ed.,Elsevier. CCPS. (1998) Guidelines for Quantitative Risk Assessment in Chemical Process Center for

Chemical Process Safety.

CCPS. (1992) Plant Guidelines for Technical Management of Chemical Process SafetyRevised Edition, Center for Chemical Process Safety/AIChE.

Journals & Internet Resources Loss Prevention Bulletin Journal of Loss Prevention in the Process Industries Process Safety Progress Journal of Hazardous Materials Fire Safety Journal Journal of Safety Research http://www.csb.gov/ http://www.cdc.gov/niosh/topics/chemical-safety/

ASSESSMENT STRATEGY & EVALUATIONThe course evaluation for posgraduate and last year undergraduate students will consist on weekly

course-works (15% each module, 60%) and one final team applied project (40%).

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