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Process Safety Life Cycle Management: Best Practices and Processes
 

Process Safety Life Cycle Management: Best Practices and Processes

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Learn how to transform your current process safety program to deliver intelligent and  integrated safety solutions that can directly affect the bottom line, while simultaneously improving process ...

Learn how to transform your current process safety program to deliver intelligent and  integrated safety solutions that can directly affect the bottom line, while simultaneously improving process and personnel safety.

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    Process Safety Life Cycle Management: Best Practices and Processes Process Safety Life Cycle Management: Best Practices and Processes Presentation Transcript

    • Webinar ”The Challenges of Managing the Safety Life Cycle” 2-3 pm Thursday, August 15, 2013 Host: Rick Stanley • Former chairman of the API Subcommittee on Pressure Relieving Systems and the API Subcommittee on Instrumentation and Control Systems. • Over 30 years of process industry experience managing , developing and implementing SIS standards and practices Register now at: https://attendee.gotowebinar.com/register/8843352583045147648 Powered By: Takeaways from this webinar series include :  Understanding the impact of implementing the Safety Life Cycle on the culture of your facility , across disciplines  Identifying common obstacles to effectively implementing the Safety Life Cycle  The tools and strategies that can effectively overcome these obstacles  How you can transcend the negative perceptions of compliance by using the Safety Life Cycle to drive efficient and more profitable operations Aligning your facility with ANSI/ISA-84 & IEC61511 standards can appear to be an insurmountable task. It doesn’t have to be. Join us August 15th for the start of the free webinar series: “Process Safety Life Cycle Management: Best Practices and Processes You Should Adopt” to learn how to transform your current process safety program to deliver intelligent and integrated safety solutions that can directly affect the bottom line, while simultaneously improving process and personnel safety. Designing, operating and maintaining safe operations in the process industry is no easy feat. The challenge is amplified by increasing compliance costs and leaner operations. To remain competitive, managers in the process industry must standardize compliance activities, develop & track safety performance indicators, and secure sufficient resources to close gaps.
    • Process Safety Life Cycle Management: Best Practices and Processes The Challenges of Managing the Safety Life Cycle Practical. Simple. Cost Effective.
    • Today’s Topics • Why We’re Here • Current Challenges of Safety Life Cycle Management • A Solution: ProSys DR
    • Why We’re Here Basic Investigative Findings  No or poor hazards analysis  No clear definition of protective system requirements  Poor design, maintenance and procedures Phillips 66 Pasedena, TX 23 Dead Cost > $ 1B BP Texas City, TX 15 Dead Cost > $ 2B Union Carbide Bophal, India < 3,787 Dead Costs > $ 1B 19921984 2005 Petróleos de Venezuela 42 Dead Cost > $ 2B 2012 Review of general industry practices show that these root causes were not uncommon
    • Protection Layers Potential initiating causes Undesired eventProtection Layers Prevention Process Design Basic Process Control Systems Safety Critical Process Alarms Safety Instrumented Systems Mitigation Mechanical Mitigation Systems Fire and Gas Systems Plant Emergency Community Emergency Implementing and maintaining protective layers requires a team effort. From the Plant Manager to the Technical Authority…to the Operator.
    • Evolution of Regulations and Standards 19961992 2000 2003 2004 OSHA – 1910.119 Process Safety Management of Highly Hazardous Chemicals IEC 61511 Recognized as world standard on Safety Instrumented Systems ISA S 84 “Application of Safety Instrumented Systems for the Process Industries” ANSI / ISA S84.01 - 2004 * Replaces ISA 84 - 1996 - OSHA has recognized ISA S84 as representing good practices for protective instrumentation OSHA’s National Emphasis Program Directive CPL 03-00-010 Oil Refineries Directive 10-05 (CPL2) Chemical NEP Regulations are a means, not the end, in running a safe operation.
    • Safety Life Cycle IEC 61511 provides a formalized way to manage Instrumented Protective Systems throughout a plant’s service life
    • DocumentationOperations Maintenance Safety Function Design Management Obligations The Challenge: Effectively managing the Safety Life Cycle requires teamwork between mulitple disciplines, departments, and even companies. Resources are limited. Lack of Continuity Disparate data Paperwork Overload Inconsistent reporting formats Lack of Sharing between Organizations Loss of Data Personnel Turnover Complicating Factors Safety Function ID Workplace Safety Initiative Overload
    • Managing the Safety Life Cycle  Conceptual Process Design  Hazard and Risk Analysis  Apply non-SIS Protection Layers  Define SIL  Develop SRS  Perform SIS Concept Design  Perform SIS detailed design  Install, commission, and test  Establish Operation and Maintenance Procedures  Establish Operate & Maintain Procedures  Pre-startup Safety Review  SIS Startup, Maint, Periodic Testing Process Safety Manager Process Engineer I&C Engineer Project Engineer Engineering Contractor Project Construction Contractor Plant Maintenance Plant Engineer Engineering Contractor Plant Operations and Maintenance Plant Engineer SLM Process Organization  PHA  LOPA  SRS  FSA  Design Documentation  Establish Operation and Maintenance Procedures  Pre-startup Safety Review  SIS Testing and Validation  FAT  Proof Testing  Integrity Compliance Activities HAZOP SIS Engineering Operations Maintenance Silos Industry Tools