operational safety

2003 ENGINEERING DESIGN SEMINAR – LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.

Operational SafetyOperational Safety

Engineering Design SeminarOctober 2006

Scott WozniakUOP Process Technology & EquipmentHealth, Safety & Environmental Manager

Engineering Design SeminarOctober 2006

Scott WozniakUOP Process Technology & EquipmentHealth, Safety & Environmental Manager


ObjectivesObjectives

Review the Elements of Operational SafetyHow Operational Safety Impacts an Engineer’s Activities– Design, – Operation, – Maintenance, and – Modification


Operational Safety OverviewOperational Safety OverviewExplosions & Fires

• Flixborough, UK (1974)• Seveso, Italy (1976) • Bhopal, India (1984)• Mexico City, Mexico (1984)• Piper Alpha, North Sea (1988)

Concerns by Many Countries• Regulations or Standards in Australia, Germany, India, UK,

USA, and so on.

Concerns by Bankers and Insurers


Major Process Hazard EventMajor Process Hazard EventA Major Process Hazard Event is defined as

– a release of a toxic or hazardous substance, – a fire, – an explosion, – a sudden release of energy or – other process-related incident,

which could result in life- threatening injury or fatality– employees, – visitors, – contractors or – persons outside the site or

cause environmental damage.


Major Process Hazard EventMajor Process Hazard Event

A potential MPHE can be virtually eliminated with a good, well-maintained

Operational Safety Program


Engineering ImpactEngineering Impact

As an Engineer……...

How are you involved in Operational Safety activities?

• Directly Involved• Provide Input


Operational Safety ElementsOperational Safety Elements

1. Operational Hazards2. Technology & Safety Information3. Engineering Design Reviews4. Process Hazard Analyses5. Procedures6. Mechanical Integrity7. Training8. Modifications9. Pre-Startup Safety Reviews10. Decommissioning/Recommissioning11. Process Incident Investigations



1. Operational Hazards - direct2. Technology & Safety Information - direct3. Engineering Design Reviews - direct4. Process Hazard Analyses - direct5. Procedures – input to HR or Operations6. Mechanical Integrity – input to Maintenance7. Training – input to HR or Operations8. Modifications - direct9. Pre-Startup Safety Reviews – input to safety10. Decommissioning/Recommissioning - direct11. Process Incident Investigations - input to safety



Balance of this session will be A brief review of each of the Operational Safety elements,The role that you play as technical experts in your plant’s Operational Safety ProgramDiscussion of any questions you may have regarding OpSafety Programs.



Element #1Element #1Operational HazardsOperational Hazards


Operational HazardsOperational Hazards

Who knows how to Identify

Operational Operational Hazards Hazards

better than aProcess Process Engineer?Engineer?



Identifying Potential Operational Hazards Feeds Into…..– New Designs– Modifications to Existing Plants/Units– Operating Procedures– Mechanical Integrity Programs– Training

Are you starting to notice a trend?



Sample ChecklistOperational HazardsOperational Hazards

WithWithMajor Process Hazard EventMajor Process Hazard Event

PotentialPotential



Element #2Element #2Technology & Safety Technology & Safety

InformationInformation


Technology & Safety InformationTechnology & Safety InformationTechnical Basis of the Operation*– Design specifications– Vendor information, including Licensor Technology Manuals

Emergency Characterization, Control& Mitigation* Design Standards, Codes and References*Exposure InformationHazards of Materials– Material Safety Data Sheets or Safety Sheets– Glossary of Terms for Better Understanding the Sheets

*Must be Documented


Technology & Safety InformationTechnology & Safety Information

Sample ChecklistSafety Factors ChecklistSafety Factors Checklist

ForForMaterial Safety Data SheetsMaterial Safety Data Sheets



Element #3Element #3Engineering Design ReviewsEngineering Design Reviews


Engineering Design ReviewsEngineering Design Reviews

What can You do during Design Reviews to Improve the Safety of Your Operations?Assess Adequacy of Controls and Safety SystemsAssess Compliance with Government Legislation and RegulationsInclude Inherently Safer Thinking



What can You do during Design Reviews to Improve the Safety of Your Operations?Assess Adequacy of Controls and Safety SystemsAssess Compliance with Government Legislation and RegulationsInclude Inherent Safety

Can you define an inherently safer design??



An Inherently Safer Design is one that……avoids hazards instead of controlling them by adding protective equipment oris safe by its very nature and not because equipment has been added to make it safer. (1)

(1) Kletz, T.A., Process Plants: A Handbook for Inherently Safer Design, (Philadelphia, PA, USA: Taylor & Francis, 1998), Chapter 1


Inherent Safety StrategiesInherent Safety Strategies

Minimize– minimizing the amount of hazardous material that is in use

Substitute– substituting less hazardous materials and processes wherever possible

Moderate– moderating the process conditions of the hazardous materials

Simplify– simplifying the equipment and processes that are used



Substitution

Moderation

Simplification

Minimization



SubstitutionUsing Hypochlorite tablets instead of ChlorineUsing Solid Catalyst instead of HF Acid or H2SO4 for Alkylation

MinimizationReducing Reactor sizeReducing Feed/Product StorageReducing the amount of hazardous chemical



ModerationUsing Aqueous NH3 instead of Anhydrous NH3Injecting diluted H2 instead of Pure H2Designing for lower pressure or lower temperature

SimplificationCooling with an exchanger rather a vacuum systemUsing more piping welds and fewer flanges



Element #4Element #4Process Hazard AnalysisProcess Hazard Analysis


Process Hazard AnalysisProcess Hazard Analysis

Why Conduct a PHA?– Improve Safety – Identify Potential Process Risks– Identify Critical Equipment– Improve Operations– Improve Procedures– Enhances Training– Understand Impacts of One Section of the Process on

Another Section–– Minimize Unplanned Emergency Shutdowns (costly)Minimize Unplanned Emergency Shutdowns (costly)



Types of Hazard Analyses–– Hazard & Operability (HAZOP) StudyHazard & Operability (HAZOP) Study–– What If? AnalysisWhat If? Analysis– Checklist– Failure Modes & Effects Analysis– Fault Tree Analysis– Process HSE Review



Types of Hazard Analyses–– Hazard & Operability (HAZOP) Study Hazard & Operability (HAZOP) Study –– for Process–– What If? Analysis What If? Analysis –– for Process– Checklist–– Failure Modes & Effects Analysis Failure Modes & Effects Analysis –– for Equipment– Fault Tree Analysis– Process HSE Review



Sample Worksheets

Hazards & Operability (HAZOP) Hazards & Operability (HAZOP) StudyStudy



Types of Hazard Analyses–– Hazard & Operability (HAZOP) StudyHazard & Operability (HAZOP) Study–– What If? AnalysisWhat If? Analysis– Checklist– Failure Modes & Effects Analysis– Fault Tree Analysis– Process HSE Review

Additional Enhancements– Facility Siting– Human Factors – Industry Guidelines



Sample Checklists

Facility Siting ReviewFacility Siting Review

Human Factors inHuman Factors inProcess OperationsProcess Operations



When to Conduct PHAs– New Process– Modifications to a Process– Periodic Revalidation (every 5-7 years) [Safety]


Is this aNew Process

Unit?

Is this anExistingProcessUnit?

Was a PHA Previously

Conducted?

PHA Revalidate thePHA

Communicateto AffectedEmployees

Report Status ofResolution to

Facility Management

Documentthe Closure

AreRecommendations

Resolved?

N Y Y

NNY

YN




Who Should Participate?– Process Expert

• Engineer• Process Specialist

– Operations Expert• Operators• Supervisors

– Maintenance Expert– PHA Expert– Instrument Expert– Others



What Steps should be followed for Identified Improvement Recommendations?– Implement the actions– Document the study and

the actions taken– Share the results



Element #5Element #5Operating & Maintenance Operating & Maintenance

ProceduresProcedures


Operating & Maintenance Operating & Maintenance ProceduresProcedures

Are you involved in Developing Operating Procedures?Types of Operating Procedures– Startup– Normal Operations– Shutdown – Emergency Scenarios

Who Periodically Reviews Your Site’s Operating Procedures?



Procedure Step (Prior)– From the extractor platform,

start the extractor drive and set the variable drive to the speed setting desired.

[No reference to proper settings.]

Not suggested

Procedure Step (Current)– Action

Start the Extractor drive and adjust the variable speed drive to the speed setting desired.

– DetailUse the drive controls located

at the Extractor Platform. Refer to the Standard Operating Instructions for initial speed setting.

Suggested



Sample Written Procedures

Startup of an Extractor (Poor)Startup of an Extractor (Poor)

Startup of an Extractor Startup of an Extractor (Recommended)(Recommended)



Are You Involved in Developing Maintenance Procedures?Who Provides the Equipment Specifications?Types of Maintenance Procedures– Notice to Operations (when work starts)– Lockout and Tag Out of Power Sources– Confined Space Entry– Equipment Repair/Replacement– Notice to Operations (when work is finished)



Emergency Response Procedure– How are Plant Personnel Warned?– Is There a Plant Emergency Response Team?– Are Outside Emergency Responders Involved?– How Often is the Emergency Procedure Tested?– Who Helps Operators Understand How to Make

Their Units Safe During an Emergency? – Who Designates Types of Emergencies?



Element #6Element #6Mechanical Integrity ProgramMechanical Integrity Program


Mechanical Integrity ProgramMechanical Integrity Program

Definition of Mechanical IntegrityThose aspects of production, maintenance, technical,

quality and purchasing which ensure that there is a system in place for the proper design, construction, on-going integrity and reliability of the process equipment over the entire lifecycle of the process.

Mechanical Integrity Program includes – Identifying Critical Equipment– Conducting Predictive Maintenance– Establishing Type and Frequency of Equipment

Testing





Mechanical Integrity Program includes – Identify Critical Equipment



Critical Equipment Process equipment, which if failure occurs, could result

in a Major Process Hazard Event– pressure vessels– storage vessels/tanks– piping– valves– relief and vent systems– emergency shutdown systems– controls– pumps





Mechanical Integrity Program includes – Identify Critical Equipment– Conduct Predictive Maintenance


Mechanical Integrity ProgramMechanical Integrity ProgramPredictive Maintenance

Equipment Equipment Failure Failure DetectionCategory Types Mode Cause MethodRotating Machinery

Pumps,Motors

PrematureBearing Loss

ExcessiveForces

Vibration & Lube Analysis

Compressors Blowers

Lubrication Failure

Over, under or improper lube; heat & moisture

Spectrographic & ferrographicanalysis

Electrical Equipment

Motors, Cables Starters, Transformers

Insulation Failure

Heat & Moisture Time/resistance test,I/R scans,oil analysis

Corona Discharge

Moisture, splice methods

Ultrasound

Heat Transfer Equipment

Exchangers Condensers

Fouling Sediment & material build-up

Heat transfer calculations

Containment & Transfer

Tanks, Piping Reactors

Corrosion Chemical attack

Corrosion meters, acoustic emissions

Stress cracks Metal fatigue Thickness checks





Mechanical Integrity Program includes – Identify Critical Equipment– Conduct Predictive Maintenance– Establish Type and Frequency of Testing


Mechanical Integrity ProgramMechanical Integrity ProgramPeriodic

Monitoring

Repair/ReplacementEquipment

MeasurementsMeasurementsMeet Meet

EngineeringEngineeringLimits?Limits?

Determine CorrectiveAction Analyze Problem

Yes

No

Ref: Engineer’s Digest, Feb., 1996, p.30



Obtain Types and Frequencies of Predictive Maintenance– Company Experience– Equipment Manufacturer’s Experience– Industry Data



Element #7Element #7TrainingTraining


TrainingTraining

Who in Your Operations Should Be Trained?• Operators• Maintenance • Engineers• Contractors

What Should the Training Include?


TrainingTraining

1. Understanding the Process Information– MSDSs

• Identify hazards of materials• Understand how to handle materials• Fight fires involving these materials• Disposal of materials


TrainingTraining

Sample MSDSs

RR--34 Platforming Catalyst34 Platforming Catalyst

MolsivMolsiv Adsorbents 4AAdsorbents 4A--DG 1/16DG 1/16


TrainingTraining

1. Understanding the Process Information– MSDSs


– PFDs/P&IDs• Understand the process• Know the equipment involved in the process


TrainingTraining

1. Understanding the Process Information– MSDSs [by Safety and Industrial Hygienist]


– PFDs/P&IDs• Understand the process• Know the equipment involved in the process


TrainingTraining2. Operating Procedures

– Startup, Normal and Shutdown – Emergency Scenarios– Testing of the Operators– Refresher Sessions

• Changes Made• Periodic

3. Maintenance Procedures– Maintenance Personnel– Operations Personnel, who conduct maintenance

work


TrainingTraining

Who in Your Operations Should Be Trained?• Operators• Maintenance • Engineers• Contractors

What Should the Training Include?Who Should Do The Training?

• Operations Supervision• Engineers• Maintenance Experts



Element #8Element #8ModificationsModifications


ModificationsModifications

Reassess and Address Hazards after making the Modifications– Includes Significant Changes

• Addition of equipment• Running additional (or bypass) lines• Changing operating procedures (especially batch)

– Does NOT Include Changes in Kind– Use an Appropriate PHA Method



Types of Hazard Analyses–– Hazard & Operability (HAZOP) Study Hazard & Operability (HAZOP) Study –– for Process–– What If? Analysis What If? Analysis –– for Process– Checklist–– Failure Modes & Effects Analysis Failure Modes & Effects Analysis –– for Equipment– Fault Tree Analysis– Process HSE Review


ModificationsModificationsHow is Information from PHAs for

Modifications Used?Revise Operating Procedures– Must reflect changes

Revise Mechanical Integrity Program– Add/Delete Equipment Covered– Ensure Maintenance Understands MI Changes

Ensure Operator are Aware of– Changes Made to the Process Design– Changes Made to Equipment and the MI Program– Impact on Procedures/Highlighting the Changes



Sample Checklist

Facility & Operational Change Facility & Operational Change ReviewReview



Element #9Element #9PrePre--Startup Safety ReviewsStartup Safety Reviews


PrePre--Startup Safety ReviewsStartup Safety Reviews

When to Conduct PSSRs– New Process/Facility– Significantly Modified– Significant Procedural Changes– Recommissioned/Idled Process

Documentation– Identify Corrections,– Assign Responsibilities and– Ensure that Action Items are Closed


PrePre--Startup Safety ReviewsStartup Safety Reviews

Sample Checklist

PrePre--Startup Safety ReviewStartup Safety Review



Element #10Element #10Decommissioning/Decommissioning/RecommissioningRecommissioning


Decommissioning / Decommissioning / RecommissioningRecommissioning

What is Decommissioning?– Removing process equipment from service, isolating

and securing the equipment from operations.– Do not plan to use the equipment anytime in the near

future.How is Decommissioning different from Idling? – Temporary discontinuation of an operation according

to accepted shutdown procedures.– There is a plan to restart the operation in the near

future.



Establish Procedures– Review Impact on Active Operations

• Temperature Control• Pressure Control

– Emptying Vessel, Equipment and Lines– Blinding/Disconnecting

Maintain Sound HSE Performance– Proper Maintenance– Fire Fighting Capability



Sample Checklists

Idling & Decommissioning Idling & Decommissioning PlantsPlants

RecommissioningRecommissioning PlantsPlants



Element #11Element #11Process Incident InvestigationsProcess Incident Investigations


Process Incident InvestigationsProcess Incident Investigations

What should be Investigated?– Process-Related Incidents

• Actual• Near Misses

What are you trying to Determine?Root Causes– Conditions– Actions

Why? Why? Why? Why? Why?


Uranium Processing PlantUranium Processing Plant“Can It happen Here?” page 47,Newsweek, Oct. 11, 1999



What are some of the Root Causes that came out of the Investigation of this Incident?



What are some of the Root Causes that came out of the Investigation of this Incident?– Inadequate Procedures

• Not specifying quantities of enriched uranium• No emphasis on why the materials needed to be

added slowly– Inadequate training and testing



What are some of the Root Causes that came out of the Investigation of this Incident?– Inadequate Procedures

• Not specifying quantities of enriched uranium• No emphasis on why the materials needed to

be added slowly– Inadequate training and testing


Process Incident InvestigationsProcess Incident InvestigationsFor Any Incident Investigation, How Can We Prevent Recurrence?– Understand the Problem that Caused the Incident– Correct the Problem – Learn and Apply Solution to Similar Operations

& Equipment – Share the Resolution with Other Units– Communicate with Plant Personnel– Revise Future Designs– Share with

• Other Company Sites• Industry (if possible)


Engineering ImpactEngineering Impact

As an Engineer……...

How are you involved in Operational Safety activities?

• Directly Involved• Provide Input


Field Safety for EngineersField Safety for Engineers

Parting Tips for Personally Staying Safe– Preparation– Personal

Protective Equipment

– Medical


Field Safety for EngineersField Safety for Engineers

UOPUOPField Safety HandbookField Safety Handbook

operational safety

Documents

uop llc technical information

written permission of

confidential nature

engineers activities

processrelated incident

environmental damage

mexico city

sudden release of energy