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Safe Management of Ammonia Refrigeration Systems – May 2017 in Grantham

Ammonia Process Safety Management

Mark Roxburgh

Mercury Technologies Ltd.

Safe Management of Ammonia Refrigeration Systems – May 2017 in Grantham Slide 2

PSM – What is it?

Set of tools for managing a hazardous process

Hardware & Procedures

Preventive & Reactive

It is an ongoing programme

Not a “Snapshot” risk assessment

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PSM – The Tools

1. Information 2. Mechanical integrity 3. Operating procedures 4. Training 5. Employee participation 6. Incident investigation 7. Management of change 8. Non-routine work authorisations 9. Contractors 10. Emergency response 11. Pre-commissioning review 12. Review 13. Hazard analysis

Safe Management of Ammonia Refrigeration Systems – May 2017 in Grantham Slide 4

1. Information...

MSDS

Flow diagrams & P&IDs

Drawings

Press/temp limits posted

Test certificates

Manuals

Load and charge calculations

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2. Mechanical integrity...Major hardware

Inspections – each item of hardware

Daily log

PM

PSSR

Calibrations

Manuals up-to-date

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2. Mechanical integrity...peripheral hardware

Ventilation

Ammonia detection

Beacons & alarms

Relief valves

Signage, labels, tags

PPE

Building layout, lighting

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3. Operating procedures...

Start & stop, normal & emergency

Oil drain

Charging

LOTO

Confined space

Opening the system

Ammonia leak

First aid

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4. Training...

Operation & maintenance

Ammonia awareness

Emergency response teams

Use of PPE

Evacuation

Spills

Refreshers for ALL

Records kept?

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5. Employee participation...

Is the a system in place to communicate safety information across the facility?

Are all level of employees involved?

Is information readily available to all

Are there clear channels of communications

Televisions

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6. Incident investigation...

System in place?

Begin in a timely manner

Team make-up – contractor

Report

Implementation of recommendations

Further actions

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7. Management of change...

Changes approved by all parties

Time enough for change

H&S impact investigated

Procedures modified

PM modified

Training modified

Safety hardware modified

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8. Non-routine work authorisations...

Permit to work

Is a system in place?

Relevant to ammonia

Monitored and recorded

Time, date, place

Hot work

Fire prevention

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9. Contractors...

Provide them H&S information

They provide you H&S information

Training

Induction

Monitoring

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10. Emergency response...

Is there a plan?

Is there a team?

Instructions for all groups?

Communication

Training – drills

First aid

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10. Emergency response...

Plume modelling Extent and severity AEGLs

Plant room leak Pressure relief valve Major outdoor spill

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10. Emergency response - AEGLs

AEGL-1 is the airborne concentration, expressed as parts per million ormilligrams per cubic meter (ppm or mg/m3) of a substance above which it ispredicted that the general population, including susceptible individuals,could experience notable discomfort, irritation, or certain asymptomaticnon-sensory effects. However, the effects are not disabling and aretransient and reversible upon cessation of exposure.

AEGL-2 is the airborne concentration (expressed as ppm or mg/m3) of asubstance above which it is predicted that the general population, includingsusceptible individuals, could experience irreversible or other serious, long-lasting adverse health effects or an impaired ability to escape.

AEGL-3 is the airborne concentration (expressed as ppm or mg/m3) of asubstance above which it is predicted that the general population, includingsusceptible individuals, could experience life-threatening health effects ordeath.

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10. Emergency response - AEGLs

AEGL-1 reversible upon cessation of exposure

AEGL-2 irreversible and/or impaired ability to escape

AEGL-3 death

10min 30min 60min 4hr 8hr

AEGL-1 30 30 30 30 30

AEGL-2 220 220 160 110 110

AEGL-3 2,700 1,600 1,100 550 390

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10. Emergency response...

Safe Management of Ammonia Refrigeration Systems – May 2017 in Grantham Slide 19

10. Emergency response...

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10. Emergency response...

Modify hardware accordingly

Feedback into emergency response plans

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10. Emergency response...

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10. Emergency response...

Detailed responses for all groups Full response documentation file

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11. Pre-commissioning...

As many of these risk management tools in place as possible

Design DSEAR RA, HA and OCA outputs in place

Testing, NDT approved

Commissioning procedures approved

Site awareness

Safe Management of Ammonia Refrigeration Systems – May 2017 in Grantham Slide 24

12. Reviews...

1yr – 2 yr – 3yr

Following significant changes

Following significant events

Procedure used - relevant

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13. Hazard analysis...

Various techniques• HAZOP – Hazard and Operability Analysis

• FMEA – Failure Mode and Effects Analysis

• FTA – Fault Tree Analysis

• Checklist

• What-If

• What-If Checklist best suited

Safe Management of Ammonia Refrigeration Systems – May 2017 in Grantham Slide 26

13. Hazard analysis...

Each major item of equipment

Human factors

Site issues

Instrumentation

Shutdown/Start-up

Emergency situations

Safe Management of Ammonia Refrigeration Systems – May 2017 in Grantham Slide 27

13. Hazard analysis...

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13. Hazard analysis...

Safe Management of Ammonia Refrigeration Systems – May 2017 in Grantham Slide 29

Finally...

Since DSEAR makes reference to many of the above, a DSEAR risk assessment can now be carried out