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Industry Practice of Process Safety

Contents

• Process Safety (PS)

• Industries practicing PS

• PS applicability in Chemical Engineering profession.

• PS throughout project lifecycle

• Case studies and its relation to your profession.

• Hazard analysis

• Process Safety Management (PSM)

• Inherently Safer Design (ISD)

What is process safety?Keeping medium where it designed to be….

Vessel information

Medium information

Mechanical integrity

Operator training and competency

Operating procedure

Management of Change

What is process safety?

Centre of Chemical Process Safety (CCPS)

Industries & PS

Process Safety vs ProfessionDesign Engineer

Project Engineers

Process Engineers

Operation Engineers

Safety Engineers

Safety Consultants

Academician

Researcher

Fabrication Engineer

Procurement

Inspection Engineers Professional Engineer

Quality Engineer

For a Process Plant to exist…

Concept of process

Process design stage

Engineering stage

Construction Stage

Commissioning stage

Operative stage

Design Engineer

Design Engineer

Design /project Engineer

Project / Process Engineer

Project / Process Engineer

From Plan to Production

Why is it so important for my profession..??

• Naphtha Hydrotreater (NHT) Unit• Rupture of heat exchanger.• Heat Exchanger was severely degraded due to long term cracking damage from High

Temperature Hydrogen Attack (HTHA).

Why is it so important for my profession..??Root causes / contributing factors:• Metallurgical failure:

Fabricated with Carbon steel instead steel alloy which has higher temperature resistance.

Root causes / contributing factors:• Process control failure:

Combined temperature probe, no individual temperature outlet

Fabrication Engineer

Design Engineer

Root causes / contributing factors:• Performance study failure:

Corrosion studies did not recommend HTHA inspection for Heat Exchanger. Studies were performed using design temperature, not operating.

Process Engineer / Consultant Root causes / contributing factors:

• Procedural failure: Leaks observed during start up which was frequent and being treated as ‘normal’ as excepted to cease when reach operating temperature

Operation Engineer

Why is it so important for my profession..??

• Imperial sugar- dust explosion in silo.• 14 killed & 42 injured. • Sugar dust accumulation were noticeable due to poor dust management ( dust

collector, dust cleaning method and continuous spillage and blockage).• Dust in contact with ignition source (overheating of pump bearing).

Why is it so important for my profession..??Root causes / contributing factors:• Poor design:

Poor design of dust managing system allowing of dust escape.

Root causes / contributing factors:• Poor risk assessment:

Conducted by financial risk consultant

Design Engineer

Consultant

Root causes / contributing factors:• Lesson never learned:

Experienced non significant evet of explosion and fire.

Operation Engineer

Root causes / contributing factors:• Failure to address audit findings:

Previous audit identified improvement needed on dust management, no follow up to take action.

Operation Engineer

Ok….how would I know…..??

Hazards that exist

Rules

Risk involved

Codes & Standards

Practices

Experience

Emerging hazards

Is the thoughts that counts

Analyzing hazards and risk

HAZIDHAZOP

QRA

What If

Bow TIe

FMEAFTA

SIL

LOPA

Industries application of risk studies

Process Hazard Analysis (PHA) - HAZOP

HAZOP

HAZOP studies supports acquisition:• Due diligence • Economical value of the asset.

Process Hazard Analysis (PHA) - HAZOPHAZOP Study for Power Plant Construction – Khoakanun Clean Energy Project, Thailand–Detail Design stage.


The participants:


HAZOP Assumptions:

• Causes within the node under study.• Failure of primary or secondary protections are not

considered as cause of deviation. • A single check valve considered as acceptable safeguard

against reverse flow.• No double jeopardy – single failure result in deviation of

process condition acceptable.• One train of identical trains will be reviewed instead of both.


Recommendations:

• Updating of P&IDs.• Addition of process monitoring probes such as temperature

and pressure.• Identification of process safeguarding system such PALL

(Pressure Alarm Low Low).• Installation of physical protection such as check valves to

prevent gas backflow.• Verification of hydraulic calculation (loading) for the Plant. • Development of operating procedures.

HAZOP Study for Power Plant Construction – Khoakanun Clean Energy Project, Thailand–Detail Design stage.

Process Hazard Analysis (PHA) - HAZOPHAZOP Study for Fatty Alcohol Plant expansion- Conceptual stage- OleochmicalPlant – Port Klang


Challenges:

• Composition of participants.• Experience and knowledge of participants.• Often design and cost issues takes center stage.• During detailed design stage, conceptual issues

faced.• Disagreement situation between asset owner and

constructor. • Timeline.

Managing process safety

• Continual thoughts, awareness and practices of safety & risk management being put in place in every aspects of ‘Plan to Production’ journey will signify the management of process safety.

Process Safety Management (PSM)


• PSM standards throughout industries are almost similar.

• Elements can varies (eg: 8 to 14 elements).• But the objectives are same – safe operation. • Many MNC companies takes center stage in playing

championing PSM.

US OSHA Requirement 29 CFR.1910.119


To elaborate few them….

Chemical / technology / equipment information. Objective:

knowledge and control of operation.

Element that provide guide on performing PHA –

HAZOP/FMEA/SWIFTObjective: Hazard id and control


To elaborate few them….

Written operating procedures in place providing accurate operating

information of asset. Objective: Knowledge & control of operation.

Requires trg and competency in place for personnel. Objective:

Knowledge & control of operation

Your journey ….Process Safety Management (PSM)

Engineer Middle Management

Top Management

PSM selected elements Responsibility of PSM elements compliance

PSM as Business KPIWay of achieving HSE

& Business Goal

Inherently Safer Design - ISD

Inherently Safer Design - ISDSeparation of LQ from process area by blast/ firewall

Exhaust release points are routed away from sensitive areas, i.e. crane cabin, helideck

Risers and wellheads are located on BO-D WHRP 70 m away from BO-A CPP

3 x 50% Davit-Launched TEMPSCs

25-men life raft; Four (4) life rafts are provided on the Cellar Deck

Inherent Safety is crucial integral part of the project lifecycle.

Inherently Safer Design - ISD

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