You are on page 1of 32

Industry Practice of Process Safety

The worlds leading sustainability consultancy

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
Operating procedure
Medium information

Operator training and


competency

Management of Change

Mechanical integrity

What is process safety?

Centre of Chemical Process Safety (CCPS)

Industries & PS

Process Safety vs Profession


Academician

Design Engineer

Fabrication Engineer

Project Engineers
Researcher
Process Engineers
Procurement

Operation Engineers

Safety Engineers
Quality Engineer
Safety Consultants
Inspection Engineers
Professional Engineer

For a Process Plant to exist


Design Engineer

Concept
of process

Process
design
stage

Design /project Engineer

Engineering
stage

Construction
Stage

Project / Process Engineer

Commissioning
stage

From Plan to Production


Design Engineer

Project / Process Engineer

Operative
stage

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
Design Engineer
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

Fabrication 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

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.

Design Engineer

Root causes / contributing factors:


Lesson never learned:
Experienced non significant evet of
explosion and fire.

Root causes / contributing factors:


Poor risk assessment:
Conducted by financial risk consultant

Consultant
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

Operation Engineer

Ok.how would I know..??


Hazards that exist

Practices

Emerging hazards

Risk involved
Codes & Standards

Rules

Experience

Is the thoughts that


counts

Analyzing hazards and risk


HAZID

HAZOP
What If

Bow TIe

FTA

FMEA
LOPA

QRA
SIL

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) - HAZOP


HAZOP Study for Power Plant Construction Khoakanun Clean Energy Project, Thailand
Detail Design stage.

Process Hazard Analysis (PHA) - HAZOP


HAZOP Study for Power Plant Construction Khoakanun Clean Energy Project, Thailand
Detail Design stage.
The participants:

Process Hazard Analysis (PHA) - HAZOP


HAZOP Study for Power Plant Construction Khoakanun Clean Energy Project, Thailand
Detail 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) - HAZOP


HAZOP Study for Power Plant Construction Khoakanun Clean Energy Project, Thailand
Detail Design stage.

Process Hazard Analysis (PHA) - HAZOP


HAZOP Study for Power Plant Construction Khoakanun Clean Energy Project, Thailand
Detail Design stage.

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.

Process Hazard Analysis (PHA) - HAZOP


HAZOP Study for Fatty Alcohol Plant expansion- Conceptual stage- Oleochmical
Plant 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.
Element that provide guide on
performing PHA
HAZOP/FMEA/SWIFT
Objective: Hazard id and control

Chemical / technology /
equipment information. Objective:
knowledge and control of
operation.

Process Safety Management (PSM)


To elaborate few them.

Requires trg and competency in


place for personnel. Objective:
Knowledge & control of operation

Written operating procedures in


place providing accurate operating
information of asset. Objective:
Knowledge & control of operation.

Process Safety Management (PSM)

Process Safety Management (PSM)

Your journey .
Top Management
Engineer

PSM selected elements

Middle Management

Responsibility of PSM
elements compliance

PSM as Business KPI


Way of achieving HSE
& Business Goal

Inherently Safer Design - ISD

Inherently Safer Design - ISD


Separation 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% DavitLaunched
TEMPSCs

25-men life raft; Four (4)


life rafts are provided on
the Cellar Deck

Inherently Safer Design - ISD


Inherent Safety is crucial integral part of the project
lifecycle.