20120315 Management of Process Safety R1.pptx

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1. Management of Process Hazard API RP-750

2. Process Hazard Management (API RP 750) Objective of Process Hazard/Safety Management (PSM) is prevention of catastrophic release through : Process Safety Information (PSI) Process Hazard Analysis Management of Change (MOC) Operating Procedures Safe Work Practices Training Assurance of quality and mechanical integrity of critical equipment Pre-Start-Up Safety Review (PSSR) Emergency Response and Control Investigation of process-related incidents Audit of PSM systems

3. PSM Principle and Scope Principle of This Recommended Practice (RP) PSM is an integral part of the design, construction, maintenance and operation of facility The RP is intended for facility that use, produce, process or store following substance: Flammable or explosive substance  quantity and condition that a sudden cause catastrophic release Toxic substance that have Substance Hazard Index (SHI) greater than 5000 and present in amount above treshold quantity

4. PSM Applicability This RP is developed for refineries, petrochemical operation and major processing facilities, except: Distribution, retail and jobber operations (contractor) LNG facilities, pipeline and transportation by US DOT Oil & Gas well drilling, services and production covered by US Mineral Management Services (MMS) Storage of flammable or combustible nonreactive, bulk liquid at atmospheric pressure without benefit of chilling or refrigerant Storage of hydrocarbon fuel solely for on-site consumption Natural Gas processing excluded process with extraction process of LPG

5. 1) Process Safety Information PSI element : Process Design Information PFD, process chemistry , maximum intended inventory, acceptable upper and lower limit i.e. temperature, pressure, flow Process Design information could be developed in conjuction with Process Hazard Analysis Mechanical Design Information material of construction, P&ID, Electrical Are Classification, design and basis of relief system, design of ventilating system, description of shutdown and interlock Mechanical design information could be developed from available equipment and inspection records

6. 2) Process Hazard Analysis (PHA) Purpose of PHA Minimize likelihood of occurance and consequences Methodology General Identification Assessment Alternative Initial Analysis : existing and new facilities Periodic Analysis : 3-10 years Analysis Team Knowlegeabele person in engineering, process, prod.

7. 3) Management of Change (MOC) Type of Change Change in Technology, i.e. Bypass connection, change operating procedure Change in Facilities, i.e. Temporary connection, replacement of equip.different from original Procedure should consider : Process and mech.design basis for proposed change Analysis of HSE consideration, incl.PHA Necessary modification of operating procedures Communication of proposed change and consequence Required authorization Duration of change

8. 4) Operating Procedures Written Procedure should incl : R&R of facilities’ operating area Clear instruction ~ PSI Operating Condition and steps of operation Initial S/U, normal op.,S/D, emergency, S/U during T/A Operating limit where consideration are present Steps required to avoid deviations, function of safety system OHS Consideration, i.e. MSDS explanation Operation procedure  before start up Review periodically : 3 – 5 years

9. 5) Safe Work Procedures (SWP) SWP for Operation, maintenance, and modification activities Opening Equipment, LOTO, Confined Space Control of Material Specification and inventories critical to process safety QC procedure should be established to ensure all materials received and used meet the specifications

10. 6) Training Initial Training Required knowledge and skill for all personnel to carry out duty and responsibility, incl. S/U and S/D Communication of Change To all operating personnel before operate the facility Periodically, at least per 3 year Procedure to ensure adequate retention of required knowledge and skills Qualified Instructor Documented

11. 7) Quality Assurance and Mech.Integtrity Critical equipment: designed, fabricated, installed and maintained in a manner Written QC procedure during Fabrication Checks and Inspection before start up (installation) Ensure Mechanical Integrity in Maint.System: Maintenance procedure and work practice (API 2007) Training of maintenance team prior procedure application QC procedure to ensure maintenance material and spare equipment and part as per design Procedure to ensure maintenance employee and contractors are qualified Procedure to ensure ‘change’ are review & implemented

12. 8) Pre-Start-up Safety Review (PSSR) PSSR performed for new and modified facility PSSR element : Construction is in accordance w/ specification Safety, Operating, Maintenance and Emergency Procedure are in place, as appropriate PHA recommendation already considered and completed Training of operating personnel has been completed

13. 9) Emergency Response and Control Emergency Action Plan following OSHA 1910.38(a) Employee Emergency Plan and fire prevention plans OSHA 1910.120 Hazardous Waste Operation and Emergency Response If Fire Brigade established, OSHS 1910.156 Fire Brigade Emergency Control Center , equipped w/: Plant Layout and Community Plan Utility drawing, included fire-water system Emergency Lighting Emergency Communication Reference : plan, MSD S, phone number List of emergency equipment (location), mutual aid info Access to meteorogical

14. 10) Investigation of Process Incident Finding of investigation should be kept by facility for possible use in next PHA update Management  system to determine and document finding  f/u 11) Audit To ensure effectiveness of performance 1-10 Audit interval 3-5 years Audit team : knowleageable in process and specialist deemed necessary f/u Report to Management