Process Safety

In order to understand process safety one needs to understand its meaning when put
into a context that agrees with our situation of interest.

Process, is a series of actions or steps taken in order to achieve a particular end. When
one puts this definition into context it has the following meaning:
An industrial process is one that alters raw materials or substances by subjecting them
to different conditions such as pressure, temperature, and/or mixing them in order to
change their molecular composition in controlled conditions, etc. and resulting in a
change of the original matter or raw material.
Some processes make the production of high demand material or substances very
economical, thus changing it into a commodity; i.e. the processing of Alberta oil sands
makes it economically feasible for society to use in a large scale its derivative materials
or products such as gasoline after processing.

Safety is a condition or state in which there is relatively very low probability of injury,
loss or illness. Safety is the condition of being protected from danger, risk of harm, or
injury. One can say that safety is achieved when there is a relatively very low level of
danger, risk of harm, or injury.

From the definition of process and safety above, one can distinguish between
functionally safe or hazardous processes. Process safety applies to those processes
that are inherently hazardous and need controls in order to achieve the condition of
being functionally safe.
Process safety is a disciplined framework of activities with the intent to achieve and
maintain the integrity of hazardous processes by applying recognized and accepted
good design, engineering, and operating practices.

There are three new words being used above that require more explanation so that one
can have the complete picture. These words are danger, hazard, and risk. A hazard is
defined to be a situation that has the potential to cause harm. Danger is an exposed
hazard. And risk is the combination of the probability of occurrence of harm and the
severity of that harm.

There are different types of hazards such as biological, physical, chemical, radioactive,
mechanical, electrical, etc. Process hazards are special in the sense that they are not
always exposed for us to see. In the case of physical or electrical hazards almost
always are exposed. Examples of exposed hazard are those that are relatively easy to
distinguish and if one pays attention one can avoid them. When one sees a sign that
says danger we pay attention because there is an exposed hazard that can cause
harm. Process hazards on the other hand are characterized by being hidden dangers.

Usually, there are fences or yellow tapes and danger signs when a hazard is exposed.
This is done with the purpose to avoid exposure to the potential cause of harm. On the
other hand, it is difficult to deal with process hazards for two main reasons: one is that
they are not obviously exposed, they are hidden, and second because they are
extremely destructive, losses are usually high, and consequences severe.
The best way to deal with process hazards is to maintain the integrity of hazardous
processes by applying recognized and accepted good design, engineering, and
operating practices so that their potential harm is not released.

The way to maintain the integrity of hazardous processes, once they have achieved the
state of being functionally safe, is to implement a process safety management strategy.
Process safety management program will ensure that the hazardous process will stay in
the functional safe state.
Physical hazard exposed (Danger)
























Process hazards hidden












See Pemex accident
Youtube













http://www.youtube.com/watch?v=flyk3qfUQSs




























Functional Safety

If one understands process safety then functional safety concept is easy to grasp.
Quoting the definition from the International Electro-technical Commission, (IEC):
Functional safety is part of the overall safety relating to the process and the basic
process control system, BPCS, which depends on the correct functioning of the safety
instrumented system, SIS, and other protection layers.

One can say that Functional Safety is a situation or state that has to be achieved. For
example, a process can achieve the state of being functionally safe.

I will use the words for defining what process safety is, and then add the additional
information that characterizes functional safety in context of the scope and purpose of
IEC standards.

Functional safety in the process industry is a disciplined framework of activities with the
intent to achieve and maintain the integrity of hazardous processes and the basic
process control system, assuming that both are dependent on the reliable correct
functioning of a safety instrumented system, and other independent protection layers.
The activities that form the disciplined framework to be applied are expressed in the
recognized and accepted good design, engineering, and operating practice, IEC 61511-
1/2/3.

The concepts or definitions of functional safety and process safety are the same with
respect of their purpose and intent. However, functional safety when put into context of
the IEC standards refers to the dependence and reliable correct functioning of a safety
instrumented system and other independent protection layers. Functional safety deals
with the engineering and design of the safety instrumented systems and how they
interact and respond with respect to other safeguards and the control systems used for
process control; with the intent and purpose of achieving the state of being functionally
safe.

It is important to mention that once the functional safe state is achieved, its integrity
would have to be ensured by implementing a functional safety management strategy.
If functional safety management program does not exist, or is not implemented, then the
process will eventually deteriorate and it will no longer be functionally safe.
Maintenance, proof testing, etc. are a conditional part of maintaining the integrity of the
safeguards, including the safety instrumented system.