meeting today’s societal expectations: process risk ...plant layout 2.1 indoor versus outdoor...
TRANSCRIPT
1
Tim Overton
Chief Process Safety Engineer
The Dow Chemical Company
Meeting Today’s Societal Expectations: Process Risk Management Programs of
The Dow Chemical Company
2
An Unsettled Public
Growing Concerns About Safety
in the Chemical Industry
3
An Overview
• Dow’s Commitment to EH&S Excellence
– Drive to Zero
– 2005 EH&S Goals
– 2015 Sustainability Goals
• Developing a Rigorous Process Safety Program
– Work Processes and Operating Discipline
– Metrics
– Culture
– Personalization
• The Role of the Chemical Industry
4
5
Goals set in 1996 for 2005
Injuries and Illnesses: Reduce 90%
LOPCs: Reduce 90%
Transportation incidents: Reduce 90%
Process Safety incidents: Reduce 90%
Motor vehicle incidents: Reduce 50%
6
Performance vs. Goals1996-2005
• Process Safety: Goal to reduce by 90%
PSCM Performance vs M&E MI Plan Target
193
193
156
127
103
83
67
5544
3629
2319
0
20
40
60
80
100
120
140
160
180
200
1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005
PS
CM
Co
un
t
Baseline
Target - constant % improvement PSCM Performance vs M&E MI Plan Target
193
143137
110
8475
81 7867
52 56
138
193
156
127
103
83
67
5544
3629
2319
0
20
40
60
80
100
120
140
160
180
200
1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005
PS
CM
Co
un
t
ActualBaselineTarget - constant % improvement
Actual reduction: 71%
7
• LOPCs:Down 72%
• Transportation incidents:Down 65%
• Injury and Illnesses:Down 84%
• Motor vehicle incidents:Down 39%
’96
’05
’96
’05
’96
’05
’96
’05
Performance vs. Goals1996-2005
8
Putting it another way…
During the past 10 years…
• 13,000 employees did not suffer an injury or illness
• 10,500 LOPCs did not occur
• 150 motor vehicle accidents, with potential to cause injury or fatality did not occur
• 1,100 Process Safety incidents did not occur
9
2015 Sustainability Goals
CollaborateListening, learning, talking and taking action –
we’re helping our communities to be better places to live and work for everyone.
ElevateWe seek to understand
our impact on global
ecosystems, and will work
towards the efficient and
effective use of our
precious resources.
InnovateWe will use our technology to
develop products to improve the quality of life around the world, while
ensuring those products are managed safely throughout their
lifecycles.
This is sustainability at Dow.
PerformWe’re raising the sustainability bar, setting targets to
address some of the world’s most pressing challenges and tracking our performance publicly,
year after year.
10
2015 Sustainability Goals
By 2015, Dow will achieve, on average, a 75 percent improvement based on 2005 results.
• Injury rate of 0.08 for Dow and contractors combined
– 75 percent reduction in severity, and NO FATALITIES
• All sites combined will have fewer than 75 LOPCs
• All sites will reduce process safety incidents by 75 percent, reduced severity rate by 95 percent
• All Dow employees combined will reduce the MVA rate to 1.5
• Additional goals: security, waste and emission reduction or
resource conservation
• ….(other goals)
11
Pyramid of Process Safety Performance
Organization, Work Processes and
Operating Discipline
12
Organization, Work Process and Operating Discipline
• Process safety beings with the design and control of a facility
Organization:• 25 Technology Centers worldwide• 30 full-time process safety professionals (Process Safety
Technology Leaders)• Chief Process Safety Engineer• Dedicated analytical research roles for reactive chemicals
program• Strong dedication to process safety issues by internal Process
Automation and Process Engineering functions• Key Manufacturing and EH&S roles: Production Leaders,
Business Manufacturing Leader, EH&S BOL, Site EH&S Responsible Care Leaders
13
Dow’s Process Safety History
PrePre--19601960 -- Fire Protection EngineeringFire Protection Engineering
19631963 -- Corporate Safety & Loss Prevention Department formed Corporate Safety & Loss Prevention Department formed
19641964 -- Fire and Explosion Index (Risk Analysis)Fire and Explosion Index (Risk Analysis)
19661966 -- Reactive Chemicals ProgramReactive Chemicals Program
19741974 -- Loss Prevention Principles issuedLoss Prevention Principles issued
19761976 -- Minimum Requirements (First Edition)Minimum Requirements (First Edition)
19781978 -- Operations Practices (Minimum Requirements Emphasis)Operations Practices (Minimum Requirements Emphasis)
19821982 -- Fire Protection Practice ManualFire Protection Practice Manual
19861986 -- Chemical Exposure Index (CEI)Chemical Exposure Index (CEI)
19901990 -- Chemical Engineering Hazard Guidelines issued. Chemical Engineering Hazard Guidelines issued.
19911991 -- Guidelines for Management of ChangeGuidelines for Management of Change
1994 1994 -- Process Risk Management Guidelines for Facilities and DistributProcess Risk Management Guidelines for Facilities and Distributionion
1994 1994 -- Guidelines for Hazard and Operability StudyGuidelines for Hazard and Operability Study
1997 1997 -- Process Safety Expertise Center establishedProcess Safety Expertise Center established
1997 1997 -- Global Reactive Chemicals Global Standard issuedGlobal Reactive Chemicals Global Standard issued
1998 1998 -- TDCC Business EH&S Risk Evaluation Work Process TDCC Business EH&S Risk Evaluation Work Process
1999 1999 -- Global Mechanical Integrity Standard issuedGlobal Mechanical Integrity Standard issued
2000 2000 -- Introduction of Layers of Protection Analysis toolIntroduction of Layers of Protection Analysis tool
14
Dow’s Process Safety History
And our “history” never stops growing. We continuously improve upon our existing programs….
PrePre--19601960 -- Fire Protection EngineeringFire Protection Engineering
19631963 -- Corporate Safety & Loss Prevention Department formed Corporate Safety & Loss Prevention Department formed
19641964 -- Fire and Explosion Index (Risk Analysis)Fire and Explosion Index (Risk Analysis)
19661966 -- Reactive Chemicals ProgramReactive Chemicals Program
19741974 -- Loss Prevention Principles issuedLoss Prevention Principles issued
19761976 -- Minimum Requirements (First Edition)Minimum Requirements (First Edition)
19781978 -- Operations Practices (Minimum Requirements Emphasis)Operations Practices (Minimum Requirements Emphasis)
19821982 -- Fire Protection Practice ManualFire Protection Practice Manual
19861986 -- Chemical Exposure Index (CEI)Chemical Exposure Index (CEI)
19901990 -- Chemical Engineering Hazard Guidelines issued. Chemical Engineering Hazard Guidelines issued.
19911991 -- Guidelines for Management of ChangeGuidelines for Management of Change
1994 1994 -- Process Risk Management Guidelines for Facilities and DistributProcess Risk Management Guidelines for Facilities and Distributionion
1994 1994 -- Guidelines for Hazard and Operability StudyGuidelines for Hazard and Operability Study
1997 1997 -- Process Safety Expertise Center establishedProcess Safety Expertise Center established
1997 1997 -- Global Reactive Chemicals Global Standard issuedGlobal Reactive Chemicals Global Standard issued
1998 1998 -- TDCC Business EH&S Risk Evaluation Work Process TDCC Business EH&S Risk Evaluation Work Process
1999 1999 -- Global Mechanical Integrity Standard issuedGlobal Mechanical Integrity Standard issued
2000 2000 -- Introduction of Layers of Protection Analysis toolIntroduction of Layers of Protection Analysis tool
2001 - Enhanced Process Risk Management Program2002 - Enhanced Layers of Protection Analysis2004 - Update to all Dow Loss Prevention Principles2006 - Enhanced Building Overpressure Analysis
…. and many more…..
Although we already had a rich tradition in Process Safety, with the integration of
best practices from UCC’s Operational Safety program we’ve added to or
enhanced several of our programs.
15
The Bow-Tie Diagram
ENGINEERING
MAINTENANCE
OPERATIONS
HAZARD
UndesiredUndesired
EventEvent
C
O
N
S
E
Q
U
E
N
C
EBarriersMitigation &
Emergency
Preparedness
Measures
THREAT
THREAT
THREAT
Courtesy of Robin Pitblado DNV
16
Work Processes and Guidelines
• Corporate-wide work processes and guidelines for implementation of Operating Discipline, Management of Change, Mechanical Integrity programs, Training, Project reviews and more
• Comprehensive “Loss Prevention Principles”: best practices, recommendations, and mandatory requirements for Dow facilities
Dow corporate
Operating Discipline
Management System
(ODMS)
Web based. Accessible
to all employees world-
wide
17
Table of Contents for Dow LPPs:
Topic
P REFACE
TABLE OF CONTENTS
1. INTRODUCTION
1.1 In t roduct ion to Loss Pr event ion P rinciples
1.2 Fir e and E xplosion Index
1.3 Chemica l E xposure Index
1.4 Pr oject Review Pr ocess
1.5 Mater ial Hazard Ident ifica t ion
1.6 Loss Prevent ion Ch ecklist
1.7 Chemica l In terr eact ivity Charts
2. P LANT LAYOUT
2.1 Indoor Versus Outdoor Plan t Opera t ions
2.2 Layout and Separa t ion of Facilit ies
2.3 Access Roadways
2.4 Sewer an d Dr ain Systems
3. ELECTRICAL
3.1 E lect r ica l Ar ea Classifica t ions
3.2 Cable Tr ay Loca t ion and Protect ion
3.3 Light in g
3.4 Pr ocess Plan t Power Systems
3.5 Motor Control Center s and Elect r ica l Rooms
3.6 Sta t ic Elect r icit y
3.7 Min er a l Oil F illed Power Transfor mers
3.8 E lect r ica l Main tenance – Predict ive/Pr event ive Main tenance
4. F IRE WATER SYSTEMS
4.1 Fir e Water Pum p and Dr iver
4.2 Spr ink ler Dr ain Test
4.3 Water Mains an d Layout
4.4 Basic Hydraulics
4.5 Fir e Water Source
4.6 Fir e Water Demand
5. F OAM SYSTEMS
5.1 Foam Protect ion Applica t ions
5.2 Foam Protect ion for Tan ks
5.3 Types of Foams
5.4 High E xpansion Foams
5.5 Foam Proport ion ing Systems
5.6 Main ta in ing Foam Systems
6. EQUIP MENT
6.1 Cooling Towers
6.2 Air-Cooled Hea t Exchanger s
Topic
6.3 Tanks and Vessels
6.4 Glass and Transpa ren t Devices
6.5 Compr essed Gas Cylinder s
6.6 Min imum Requir ements for Fiber Rein for ced P la st ic Vessels
6.7 Meta ls, Alloys and Non-Meta llic Ma ter ia ls of Const r uct ion
6.8 Indust r ia l Tr uck Classificat ions
6.9 Use of Vacuum Trucks or Vacuum Equipment wit h F lammable,
Combust ible, or React ive Mater ia ls
7. STORAGE AND HANDLING OF CHEMICALS AND UTILITIES
7.1 Flammable Liqu ids
7.2 Liquefied Pet r oleum Gases
7.3 Combust ible Liqu ids
7.4 Unstable and React ive Chemica ls
7.5 Dikes and Conta inment
7.6 Stor age Cabinets for F lammable Liqu ids and Combust ible
Liqu ids
7.7 Iner t Gases and Nit rogen Ut ility Systems
7.8 Ut ility Air Systems Including Br eath ing Air
7.9 Potable Water Systems
7.10 Utility Water Systems (Excluding Potable Water)
7.11 Ut ility Steam and Condensa te Systems
7.12 Utility Natur al Gas Systems
8. LOADING AND UNLOADING STATIONS
8.1 Tank Cars and Tank Tr ucks
8.2 Ships and Barges
9. DETECTION SYSTEMS
9.1 Fire Detector s
9.2 Combust ible Gas Detectors
10. FIRE DAMAGE CONTROL SYSTEMS
10.1 Preamble to F ir e Damage Control Systems
10.2 Use of Iner t Gas for Padding (DE LE TE D)
10.3 Wet and Dr y P ipe Spr inkler Systems
10.4 Deluge Systems
10.5 Carbon Dioxide Systems
10.6 Dry Chemica l Systems
10.7 The Use of Halon
10.8 Fireproofing
10.9 Water Curta ins
10.10 Insu la t ion for F ire Pr ot ect ion
10.11 Inspect ion , Test ing and Main tenance of F ir e Protect ion
Systems
10.12 Explosion Suppression
10.13 Fire Doors
Topic
11. COMBUSTIBLE DUSTS AND SOLIDS
11.1 Com bu st ible Dusts
11.2 Foamed Plast ics
11.3 Foamed Plast ic Insula t ion
12. BUILDINGS
12.1 Purged Control Rooms
12.2 Occupied Plant Buildings Subject to Extern al Hazards
12.3 Office Buildin gs
12.4 Warehouse Buildings
12.5 Labora tor ies
12.6 Labora tory Fume Hoods
12.7 Process An alyzer Out door Buildings/Enclosures
13. FIRED EQUIP MENT
13.1 Safety and Control of Fired Equipment
13.2 Hea t Exchange Systems
13.3 Outdoor Oil Fir ed Boiler s
13.4 Furnaces Hea t ing Flammable Mat eria ls
14. RELIEF AND VENT SYSTEMS
14.1 Pressure/Vacuum Relief Syst em s
14.2 Fla r e Systems
14.3 Flame Arresters and Detona t ion Ar rest ers
15. INSTRUMENT AND COMP UTER CONTROL
15.1 Inst rument Insta lla t ion
15.2 Emergency Shutdown
15.3 Process Con trol Computer and Business Mini-Computer
Safeguards
15.4 Safety Inst rument ed Systems
16. ROTATING P ROCESS EQUIP MENT
16.1 Crit ica l Rota t ing Equipment
16.2 Safe Operat ion of Gas Turbin es
16.3 Steam Turbine Genera tors
16.4 Deadh eaded Pumps
17. P IP ING
17.1 In t roduct ion and Scope
17.2 Defin it ions and Abbrevia t ion s
17.3 Codes and References
17.4 Piping Materia ls
17.5 Piping Materia l Specifica t ions
17.6 Piping Design
17.7 Piping Fabrica t ion
17.8 Piping Insta lla t ion
17.9 Piping Opera t ion and Maintenance
17.10 Utilit y Pipin g (DELETED)
17.11 Potable Water and Brea th ing Air (DELETED)
Topic
P REFACE
TABLE OF CONTENTS
1. INTRODUCTION
1.1 In trodu ct ion to Loss Prevent ion Pr inciples
1.2 F ire and Explosion Index
1.3 Chemica l Exposure Index
1.4 Project Review Process
1.5 Mater ia l Hazard Iden t ifica t ion
1.6 Loss Prevent ion Ch ecklist
1.7 Chemica l In terreact ivity Char ts
2. P LANT LAYOUT
2.1 In door Versus Outdoor P lan t Opera t ions
2.2 Layout and Separa t ion of Facilit ies
2.3 Access Roadways
2.4 Sewer an d Dra in Systems
3. ELECTRICAL
3.1 E lectr ica l Area Classifica t ions
3.2 Cable Tray Locat ion and Protect ion
3.3 Light ing
3.4 Process Plan t Power Systems
3.5 Motor Cont rol Centers and E lect r ica l Rooms
3.6 Sta t ic Elect r icity
3.7 Min era l Oil Filled Power Transformers
3.8 E lectr ica l Main ten ance – Predict ive/Preven t ive Main ten ance
4. FIRE WATER SYSTEMS
4.1 F ire Water Pu mp and Driver
4.2 Spr inkler Dra in Test
4.3 Water Mains an d Layout
4.4 Basic Hydraulics
4.5 F ire Water Source
4.6 F ire Water Demand
5. FOAM SYSTEMS
5.1 Foam Protect ion Applica t ions
5.2 Foam Protect ion for Tanks
5.3 Types of Foams
5.4 High Expansion Foams
5.5 Foam Propor t ion ing Systems
5.6 Main ta in ing Foam Systems
6. EQUIP MENT
6.1 Cooling Towers
6.2 Air -Cooled Hea t Exchangers
Topic
6.3 Tanks and Vessels
6.4 Glass and Transparen t Devices
6.5 Compressed Gas Cylinder s
6.6 Minimum Requirements for Fiber Reinforced Plast ic Vessels
6.7 Meta ls, Alloys and Non-Meta llic Mater ials of Construct ion
6.8 In dustr ia l Truck Classifica t ions
6.9 Use of Vacuum Tru cks or Vacuum Equipment with Flammable,
Combust ible, or React ive Mater ia ls
7. STORAGE AND HANDLING OF CHEMICALS AND UTILITIES
7.1 F lammable Liqu ids
7.2 Liquefied Petroleum Gases
7.3 Combust ible Liqu ids
7.4 Unstable and React ive Chemica ls
7.5 Dikes and Conta inment
7.6 Storage Cabinet s for F lammable Liqu ids and Combust ible
Liqu ids
7.7 In er t Gases and Nit rogen Utility Systems
7.8 Utility Air Systems Including Brea th ing Air
7.9 Potable Water Systems
7.10 Utility Water Systems (Excluding Potable Water)
7.11 Utility Steam and Condensa te Systems
7.12 Utility Natura l Gas Systems
8. LOADING AND UNLOADING STATIONS
8.1 Tank Cars and Tank Trucks
8.2 Ships and Barges
9. DETECTION SYSTEMS
9.1 F ire Detector s
9.2 Combust ible Gas Detectors
10. FIRE DAMAGE CONTROL SYSTEMS
10.1 Preamble to F ir e Damage Control Systems
10.2 Use of Iner t Gas for Padding (DELETED)
10.3 Wet and Dry P ipe Spr inkler Systems
10.4 Deluge Systems
10.5 Carbon Dioxide Systems
10.6 Dry Chemica l Systems
10.7 The Use of Halon
10.8 F ireproofin g
10.9 Water Cur ta ins
10.10 In su la t ion for F ir e P rotect ion
10.11 In spect ion , Test ing and Main ten an ce of F ir e Protect ion
Systems
10.12 Explosion Suppression
10.13 Fire Doors
Topic
11. COMBUSTIBLE DUSTS AND SOLIDS
11.1 Combustible Dusts
11.2 Foamed Plast ics
11.3 Foamed Plast ic Insu la t ion
12. BUILDINGS
12.1 Purged Cont rol Rooms
12.2 Occupied P lan t Buildings Subject to External Hazards
12.3 Office Buildings
12.4 Warehouse Buildings
12.5 Labora tor ies
12.6 Labora tory Fume Hoods
12.7 Process Analyzer Outdoor Buildings/Enclosures
13. FIRED EQUIP MENT
13.1 Safety and Control of F ired Equipment
13.2 Heat Exchange Systems
13.3 Outdoor Oil Fired Boilers
13.4 Furnaces Heating Flammable Mater ia ls
14. RELIEF AND VENT SYSTEMS
14.1 Pressure/Vacuum Relief Systems
14.2 Flare Systems
14.3 Flame Arrester s and Detonat ion Arrester s
15. INSTRUMENT AND COMP UTER CONTROL
15.1 Instrument Insta lla t ion
15.2 Emergency Shutdown
15.3 Process Cont rol Computer and Business Min i-Computer
Safeguards
15.4 Safety Instrumented Systems
16. ROTATING P ROCESS EQUIP MENT
16.1 Cr it ica l Rota t ing Equipment
16.2 Safe Opera t ion of Gas Turbines
16.3 Steam Turbine Genera tors
16.4 Deadheaded Pumps
17. P IP ING
17.1 In t roduct ion and Scope
17.2 Defin it ions and Abbrevia t ions
17.3 Codes and References
17.4 Piping Mater ia ls
17.5 Piping Mater ia l Specifica t ions
17.6 Piping Design
17.7 Piping Fabrica t ion
17.8 Piping Insta lla t ion
17.9 Piping Opera t ion and Main tenance
17.10 Utility Piping (DELETED)
17.11 Potable Water and Brea thing Air (DELETED)
18
• State Based Control - Like pressing the “Easy” button
– Dow internally developed control system beginning in 1970’s
– Automated Operator Work Processes (Startup, Shutdown, Runs steps)
– Automated Process State Degradation Handling (Abnormal SituationManagement)
– In 2001, Dow Standardized on the ABB 800xA
• Integrated Safety and Basic Automation Systems within the DCS– Partitioned TüV Certified Execution Environments
– Single Development Language
– Shared or Dedicated Sensors for BPCS and SIS Based on Requirements
• Full Simulation for Control Code Validation and Operator Training
• Reliability/Fault Tolerance– Total System Design (Hardware, System Software, Applications, Network,
Support, etc.)
– Not Sensitive to Single Point Failures
– Diagnostics
– Pre-defined Degradation Path
Dow’s Key Process Automation
Systems and Tools
State Based Control: • Plant-Wide Coordination of Startup and Degradation• Automation of Frequent Operations• Process Upsets Handled by Automation Program• Alarms Only Enabled when Required• Control Strategies are State Dependent
Benefits:• Increased productivity• Reduced variability• Improved EH&S performance• Fewer nuisance alarms• Enforces operating discipline
19
Pyramid of Process Safety Performance
Work Processes and Operating Discipline
Metrics
Loss of Primary Containment
(LOPC)
Overdue action itemsProcess Safety Near Misses
Reactive Chemical incidents
(including any unplanned
fires)
LPP Compliance & Gap
Closure
Compliance Plan status
20
Pyramid of Process Safety Performance
Work Processes and Operating Discipline
Metrics
Culture
21
Culture – Ownership and Accountability at all levels
Company and Business Leaders
• Set Performance Vision
• Provide the resources
• Hold organization accountable
• Hold themselves accountable
– Annual ratings, bonuses and career opportunities hinge on success
22
Culture – Ownership and Accountability at all levels
Plant Leaders
The most important player with respect to culture!
• Their pay and career movement must be dependent on safety performance
• Must be held responsible for results not just implementation
• Dow performs a “New Leader Review” within the first six months of any new Production Leader arriving to a new role. This NLR isintended to demonstrate knowledge/competency of the reactive chemical and process safety hazards present in the plant.
– As the final reviewer of all MOCs, we want the Production Leader to be fully aware of the hazards and mitigations in placeto prevent incidents in the plant prior to approving changes.
23
Culture – Ownership and Accountability at all levels
Plant Operators
• Where it all comes together; your front line of defense
• Employment must be contingent upon safety performance
• Plant Leader must hold employees accountable
• “Balance of Consequences” applied to behaviors
24
Culture – Ownership and Accountability at all levels
Process Engineers, Process Automation, Design
• Utilize Inherently Safer designs
• Incorporate Process Automation which will take a plant to a safestate even without operator intervention
• Follow recognized industry standards
• Emphasis the importance of Management of Change and Pre-Startup Safety Reviews whenever building or changing the process.
25
Pyramid of Process Safety Performance
Work Processes and Operating Discipline
Metrics
Culture
Personalization
26
Characteristics of Safety Performance Intangibles
• The entire organization must personalize process safety and what it means to them.
• Communication is constant, timely, and personal
• Make safety performance data relevant– go beyond the numbers
• The consequences of an incident are internalized, individually…from the operator level to the corporate leader level.
• Total ownership of performance across the entire organization
• Must be kept fresh, creativity is the key
27
Pyramid of Process Safety Performance
Organization, Work Processes and Operating Discipline
Metrics
Culture
Personalization
28
A Call to Action
Chemical Industry’s Reputation
for Safety Grows
29
Thank You