Process pengenalan system technology sebagai dasar engineering.ppt

Dasar- dasar engeenering

1. Process Technology

2. Process Technology (PT)
•Principle –
The PT provides a description of the process or operation. It
provides foundation for identifying and understanding the
hazards involved- the first step in the process safety management
effort. The PT consists of three parts:
Hazards of the material
Process design basis
Equipment design basis.

3. •Features
 Hazards of Materials
•Lists chemical and physical data
•Lists raw materials, intermediates, waste products, finished
products
 Process Design Basis
•Describes process chemistry
•Describes path to safe operation
•Includes process steps and limits
•Includes consequences of deviation from established limits
 Equipment Design Basis
•Determines PSM-critical equipment
•Describes key equipment design data
Process Technology (PT)

4. •Features - Hazards of Materials
All pertinent hazard data are listed in MSDS for each chemical
used in the process, including raw materials, intermediates,
waste products and finished products.
 Physical Data
•Boiling points, freezing points
•Vapor pressures
•Flash points, combustion limits
•Ignition temperatures
•Others
 Thermal and chemical stability data
 Reactivity data
•Reaction kinetics
•Hazardous effects of inadvertent mixing of different
materials that could foreseeably occur
Process Technology (PT)

5. Features - Hazards of Materials
 Chronic and acute toxicity data
•Oral
•Inhalation
•Skin
 Exposure limits, including Permissible Exposure Limits (PEL)
 Corrosivity data
Material Safety Data Sheets may be used to comply with this
requirement to the extent they meet the information provision.
All hazard information is communicated to and made readily
available to all employee (i.e., permanent, temporary, contract)
either involved in the process or potentially exposed to the hazard
of the material.
Process Technology (PT)

6. Process Design Basis
•It describes basis for safe operation of a process
•It defines boundaries of safe operation and testing
limits
•It must be documented, maintained and
communicated to employees ( For startup of new
facilities as well as for ongoing operation)
•It Includes consequences of deviation from
established limits

7. Process design basis shall contain -
•Block diagram
•Clear description and documentation of the process
•Chemistry, including undesirable and/or runaway
reactions.
•Maximum intended inventory of hazardous substance.
•Process steps and SOC/SOPs, including maximum,
normal and minimum range such as temperatures,
pressures, flows compositions and consequences
(safety, health, environmental) of deviation above the
maximum and below minimum.
Process Design Basis

8. •Evaluation of the consequences of deviations at each
step of the process, including those affecting safety
and health of employees
•Important - All process design documents need to be
updated at regular intervals, based on input from
MOC system.
Process Design Basis

9. Guidelines for SOPs
•Intent
 To provide a clear understanding of detailed operating
parameters and limits for safe operations.
 Explain EHS consequences of operation outside
process limits
 Describe corrective actions required to correct/avoid
deviations.
 Details steps and responsibility for action.

10. Guidelines for SOPs
•A procedure should contain :
Purpose of the procedure/activity
EHS requirement and PPEs requirement. Precautions to help
prevent exposure including administrative controls and
engineering controls.
Tasks to be performed by the Operator
Instrument readings and samples to be taken
Conditions to be maintained
Safety and Health Consideration should be clearly identified
in critical steps
Safe Operating limits for critical parameters
Operating Limits, including safe work limits, trip and alarms
related to the procedures.
Control Philosophy

11. Guidelines for SOPs
•A procedure should contain :
Consequences for deviating from these ranges, and how to
correct / avoid such deviations.
Consequences (what if analysis) of operating beyond safe
limits/ Trips existing to for safety.
Corrective and emergency actions (Emergency action for
general scenarios will be covered separately by emergency
team)
Inventory Limits
Learning from other incidents
•Wherever applicable, these can be supported by sketch
and P&IDs.

12. •Procedures should Exist for :
Initial startup
Startup following a turnaround or emergency shutdown
Normal operation
Normal shutdown
Emergency Operations
Emergency shutdown including conditions under which
emergency shutdown will take place.
Isolation and lineup of equipments
Process Emergencies
Utility Failures.
Critical Equipment Changeovers
Check lists for S/U // S/D of critical equipment / process
section
Any other activity which plant feels is relevant and critical
Guidelines for SOPs

13. •Procedures should :
Be accurate, understandable, use familiar language
Use inputs from process and design engineers and
operations and maintenance personnel
Reflect how operations are actually performed
Be thoroughly documented, dated, with revision numbers
on each page
Be reviewed and updated at regular intervals to capture
procedural, equipment, critical operating parameter,
software, and process changes
Be approved
•User should be informed of all changes
•Be familiar with critical operating procedures
Guidelines for SOPs

14. PT- Equipment Design Basis
The equipment design basis shall be documented,
maintained, and communicated to employees who
have responsibility for start-up of new facilities and
to employees who are involved in the ongoing
operation.
Design Bases:
Examples of equipment design documents and bases that shall be
included for PSM critical components, equipment, and systems are
as follows.
• Pressure relief and vent systems and devices—design basis,
datasheets and calculations (including vent headers, conservation
vents, and flame arrestors)

15. • Protective safety systems
 Interlock electrical schematics/settings
 Detection and suppression systems
 Shutdown and isolation systems
•Emergency systems
•Emergency alarm/ communication systems
•Monitoring device and sensor design
•Electrical classification
•Process ventilation system design
•Fire protection systems, including fire protection water

supply
•Process flow diagrams, including material and energy

balances
PT- Equipment Design Basis

16. •Equipment design basis, including the following,
as appropriate:
 
  
Equipment calculations
 
 
Equipment specification drawings and sheets
 
 
Equipment purchase specifications
 
 
Vessel sizes
 Vendor prints and equipment blueprint files Pump
specifications and characteristics P&IDs Materials of
construction , life basis and estimated corrosion rate.
•Pump specifications and characteristics
•Agitation design basis
•P&Ids.
•Piping systems
 
 
Pipe and valve codes
 
 
Hoses
PT- Equipment Design Basis

17.  
 
Expansion bellows/joint
• Instrument design basis, including the following, as appropriate:
• Loop or calibration sheets
• Alarms and interlock logic diagrams
 Control valve calculations
• 
 
Computer hardware and software
• 
 
Electrical diagrams
• 
 
Electrical grounding and bonding design
• 
 
Quality assurance inspection reports
• 
 
Design codes and standards employed
• 
 
Vendor instruction manuals
•As appropriate, the following design documents should
be included when they are relevant to process safety:
PT- Equipment Design Basis

18. • Basic data reports (e.g., process manual)
• Architectural and civil engineering (A&C) drawings
• Equipment arrangement drawings
• Piping flexibility analysis
• Special hangers, spring design, and sliding supports
• Insulation codes
• Power service systems design
• Heating system design
• Cooling system design
• Power service flow drawings (PFDs)
Equipment files containing the above information shall be archived
and kept up-to-date via the management-of-change element.
P&IDs shall be updated as changes are made to help ensure
consistency with field installation. Pertinent vendor’s data for all
the above shall be maintained.
PT- Equipment Design Basis

19. PT- PACKAGE
PT Package should contain
•Short process description
•PFD
•Detailed process description
•P&IDS – Updated
•MSDS
•Process chemistry
•Updated material and energy balance
•Safety valve design basis and calculation
•Plant layout drawings

20. PT- PACKAGE
PT Package should contain
•Fire Protection Systems with design basis
•Chemical Interaction Matrix
•SOP/SOC/max-min. intended inventory.
•Equipment manual
•Equipment design calculations.
•PSM critical equipment list.
•Certification letters of codes and standards for PSM critical
•QA record
•List to alarms, trip setting, interlocks
•Instrument design basis
•Electrical area classification drawings
•Power and electrical distribution detail including earthing.