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Safety

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  • The worlds leading sustainability consultancy

    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, ThailandDetail Design stage.

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

    The participants:

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

    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.

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

  • Process Hazard Analysis (PHA) - HAZOP

    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, ThailandDetail Design stage.

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

  • Process Hazard Analysis (PHA) - HAZOP

    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)

  • 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

  • Process Safety Management (PSM)

    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

  • Process Safety Management (PSM)

    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

  • Process Safety Management (PSM)

  • 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