Paul Amyotte
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Transcript of Paul Amyotte
INCORPORATION OF INHERENT INCORPORATION OF INHERENT SAFETY PRINCIPLES IN PROCESS SAFETY PRINCIPLES IN PROCESS
SAFETY MANAGEMENTSAFETY MANAGEMENT
Paul Amyotte & Attiq GorayaPaul Amyotte & Attiq GorayaDalhousie UniversityDalhousie UniversityDennis HendershotDennis Hendershot
Chilworth Technology Inc.Chilworth Technology Inc.Faisal KhanFaisal Khan
Memorial University of NewfoundlandMemorial University of Newfoundland
21st CCPS International Conference Orlando, FL (April 23 – 27, 2006)
With Thanks to TrevorWith Thanks to Trevor
INHERENT SAFETYINHERENT SAFETYWHAT YOU DO NOT HAVE CAN’T LEAKWHAT YOU DO NOT HAVE CAN’T LEAK
THE WISDOM OF KLETZTHE WISDOM OF KLETZ
OUTLINEOUTLINE
IntroductionIntroduction
Inherent Safety (IS)Inherent Safety (IS)
Process Safety Management (PSM)Process Safety Management (PSM)
PRIM AnalysisPRIM Analysis
Framework for IS in PSMFramework for IS in PSM
ConclusionConclusion
AcknowledgementsAcknowledgements
INTRODUCTIONINTRODUCTION
ScopeScope– Prevention and mitigation of process incidentsPrevention and mitigation of process incidents
ObjectiveObjective– Explicitly incorporate principles of inherent Explicitly incorporate principles of inherent
safety (IS) in a process safety management safety (IS) in a process safety management system (PSM)system (PSM)
MotivationMotivation– IS increasingly viewed as integral component IS increasingly viewed as integral component
of PSMof PSM– But more linkages between IS and PSM are But more linkages between IS and PSM are
needed to enhance use of IS principlesneeded to enhance use of IS principles
INTRODUCTIONINTRODUCTION
Previous workPrevious work– IS and dust explosion prevention and IS and dust explosion prevention and
mitigation (PSEP, JHM, JLPPI, CEP)mitigation (PSEP, JHM, JLPPI, CEP)– IS considerations in Dow F&EI and CEI IS considerations in Dow F&EI and CEI
(JLPPI)(JLPPI)– IS-based incident investigation (PSP)IS-based incident investigation (PSP)– Linkages between IS and cost of process Linkages between IS and cost of process
safety (PSEP)safety (PSEP)
Bhopal Conference (Kanpur, India – 2004)Bhopal Conference (Kanpur, India – 2004)
INHERENT SAFETYINHERENT SAFETY
Minimization: Minimization:
Minimize amount of hazardous material in Minimize amount of hazardous material in use (when use of such materials cannot use (when use of such materials cannot be avoided – i.e. elimination)be avoided – i.e. elimination)
INHERENT SAFETYINHERENT SAFETY
Substitution:Substitution:
Replace substance with less hazardous Replace substance with less hazardous material; replace process route with one material; replace process route with one involving less hazardous materialsinvolving less hazardous materials
INHERENT SAFETYINHERENT SAFETY
Moderation: Moderation:
Use hazardous materials in least Use hazardous materials in least hazardous forms; run process equipment hazardous forms; run process equipment with less severe operating conditions (e.g. with less severe operating conditions (e.g. T and P)T and P)
INHERENT SAFETYINHERENT SAFETY
Simplification: Simplification:
Simplify equipment and processes that are Simplify equipment and processes that are used; avoid complexities; make equipment used; avoid complexities; make equipment robust; eliminate opportunities for errorrobust; eliminate opportunities for error
INHERENT SAFETY
PROCEDURAL (ADMINISTRATIVE) SAFETY
PASSIVE ENGINEERED (ADD-ON) SAFETY
ACTIVE ENGINEERED (ADD-ON) SAFETY
Hierarchical ApproachHierarchical Approach
PROCESS SAFETY MANAGEMENTPROCESS SAFETY MANAGEMENT
Process safety:Process safety: the operation of facilities that the operation of facilities that handle, use, process or store hazardous handle, use, process or store hazardous materials in a manner free from episodic or materials in a manner free from episodic or catastrophic incidentscatastrophic incidentsProcess safety management:Process safety management: the application of the application of management principles and systems to the management principles and systems to the identification, understanding and control of identification, understanding and control of process hazards to prevent process-related process hazards to prevent process-related injuries and incidents (fire, explosion, toxicity, injuries and incidents (fire, explosion, toxicity, corrosivity) corrosivity) CCPS: CCPS: Guidelines for Technical Management of Chemical Process Guidelines for Technical Management of Chemical Process SafetySafety
MIACC MIACC → → CSChE: PSM Guide (3CSChE: PSM Guide (3rdrd edition) edition)
PROCESS SAFETY MANAGEMENTPROCESS SAFETY MANAGEMENT1.1. Accountability: objectives and goalsAccountability: objectives and goals2.2. Process knowledge and documentationProcess knowledge and documentation3.3. Capital project review and design proceduresCapital project review and design procedures4.4. Process risk managementProcess risk management5.5. Management of changeManagement of change6.6. Process and equipment integrityProcess and equipment integrity7.7. Human factorsHuman factors8.8. Training and performanceTraining and performance9.9. Incident investigationIncident investigation10.10. Company standards, codes and regulationsCompany standards, codes and regulations11.11. Audits and corrective actionsAudits and corrective actions12.12. Enhancement of process safety knowledgeEnhancement of process safety knowledge
PRIM ANALYSISPRIM ANALYSIS
No.No. ElementElement %%
66 Process and equipment integrityProcess and equipment integrity 23.823.8
22 Process knowledge and documentationProcess knowledge and documentation 21.221.2
44 Process risk managementProcess risk management 16.816.8
77 Human factorsHuman factors 8.98.9
55 Management of changeManagement of change 7.37.3
33 Capital project review and design proceduresCapital project review and design procedures 6.56.5
Process-Related Incidents Measure: 2004 Data (89 incidents)
PRIM 98/99 TO 2004- Element 6 ( Process & Equipment Integrity)
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
80.0%
90.0%
100.0%
PSM ELEMENT 6 - Sub-Elements
% o
f In
cid
ents
Att
rib
ute
d t
o E
lem
ent
6
98/99
2000
2001
2002
2003
2004
PRIM INCIDENT CAUSE ANALYSIS 1998/1999 TO 2004
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
80.0%
90.0%
100.0%
PSM Element Possibly Involved
% o
f T
ota
l In
cid
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An
alyz
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98/9920002001200220032004
FRAMEWORK FOR IS IN PSMFRAMEWORK FOR IS IN PSM
Elements 2 – 7 or Elements 2 – 7 or all 12 elementsall 12 elementsExample-based guidance (IS examples)Example-based guidance (IS examples)– Everyday lifeEveryday life– TechnicalTechnical– Process-relatedProcess-related
Qualitative methods (IS-based)Qualitative methods (IS-based)– Protocol Protocol → → Plan/Do/Check/ActPlan/Do/Check/Act– IS guidewords and checklistsIS guidewords and checklists– Validation with case studiesValidation with case studies
Quantitative methods (IS-based)Quantitative methods (IS-based)– Validation with case studiesValidation with case studies
Guideword Description
Minimize Use smaller quantities of hazardous materials when use of such materials cannot be avoided. Perform a hazardous procedure as few times as possible when procedure is unavoidable.
Substitute Replace a substance with less hazardous material or processing route with one that does not involve hazardous material. Replace a hazardous procedure with less hazardous one.
Moderate Use hazardous materials in their least hazardous forms or identify processing options that involve less severe processing conditions.
Simplify Design processes, processing equipment, and procedures to eliminate opportunities for errors by eliminating excessive use of add-on safety features and protective devices.
1. Accountability: Objectives and Goals1. Accountability: Objectives and Goals
Process safety is a Process safety is a corporate valuecorporate valueRequires management Requires management commitmentcommitment and and leadershipleadershipHopkins (2005): Hopkins (2005): Safety, Culture and RiskSafety, Culture and Risk– Safety culture (reporting, just, learning and Safety culture (reporting, just, learning and
flexible subcultures)flexible subcultures)– Collective mindfulnessCollective mindfulness– Risk-awarenessRisk-awareness
Hierarchy of controlsHierarchy of controls
Royal Australian Air ForceF111 Deseal/Reseal ProgramThe absence of any commitment to the hierarchy of controls is another manifestation of the priority of platforms over people (Hopkins, 2005).
2. Process Knowledge and Documentation2. Process Knowledge and Documentation
Company memory (management of Company memory (management of information)information)– Inherently Safer Design (ISD) features may Inherently Safer Design (ISD) features may
not have obvious purposes unless well-not have obvious purposes unless well-documenteddocumented
Normal and upset conditions (operating Normal and upset conditions (operating procedures)procedures)– Procedures must be current, accurate and Procedures must be current, accurate and
reliablereliable
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3. Capital Project Review and Design Procedures3. Capital Project Review and Design Procedures
Early consideration for this element + early Early consideration for this element + early consideration for inherent safety = high consideration for inherent safety = high potential impact on effective PSMpotential impact on effective PSMQuantitative techniques for hazard reviewsQuantitative techniques for hazard reviews– INSET (European Union)INSET (European Union)– Overall IS Index Prototype (UK)Overall IS Index Prototype (UK)– IS Index (Finland)IS Index (Finland)– Fuzzy-Based IS Index (USA)Fuzzy-Based IS Index (USA)– IS Index/Expert System (Singapore)IS Index/Expert System (Singapore)– Hierarchical Approach (Switzerland)Hierarchical Approach (Switzerland)
Other Examples of IS in Element 3Other Examples of IS in Element 3
Hazard Reviews:Polyethylene Facility
Siting/Plot Plan: Flixborough
4. Process Risk Management4. Process Risk Management
New quantitative tools (e.g. I2SI)New quantitative tools (e.g. I2SI)Existing quantitative toolsExisting quantitative tools– Dow Fire and Explosion IndexDow Fire and Explosion Index– Dow Chemical Exposure IndexDow Chemical Exposure Index
Existing qualitative toolsExisting qualitative tools– What-If analysis extended to What-If/Checklist What-If analysis extended to What-If/Checklist
analysisanalysis– Use of IS-based checklists in identifying both Use of IS-based checklists in identifying both
hazards and additional risk reduction hazards and additional risk reduction measuresmeasures
5. Management of Change5. Management of Change
EliminationElimination
MinimizationMinimization
SubstitutionSubstitution
ModerationModeration
SimplificationSimplification
Inherent safety involves change that must Inherent safety involves change that must be managedbe managed
Inherent safety opportunities when making Inherent safety opportunities when making process changesprocess changes
Identify Required Review and Approval Steps
Conduct Required Hazard Review
Inherent Safety Guidewords/Checklist
Implement and Follow-up
Obtain Approval
Identify Need for Change Inherent Safety Guidewords
Inherent Safety Guidewords/Checklist
Take Action to Control Hazards
7. Human Factors7. Human Factors
Operator-process/equipment interfaceOperator-process/equipment interface– IS-based WI/CL toolIS-based WI/CL tool
Administrative control versus hardware Administrative control versus hardware controlcontrol– Ideal opportunity to “name” inherent safetyIdeal opportunity to “name” inherent safety
Human error assessmentHuman error assessment– Need for objectivity in an otherwise subjective Need for objectivity in an otherwise subjective
processprocess
Giant Industries’ Ciniza Refinery (US CSB)Giant Industries’ Ciniza Refinery (US CSB)
Initiating Event
(tI )
Awareness Phase (tA)
Evaluation Phase (tEv)
Egress Phase (tEg)
Recovery Phase (tR)
Elevated Exposure Phases (EEPs)
Risk increasing with time to muster
Muster Actions
Offshore Platform Musters - SLIMOffshore Platform Musters - SLIM
Offshore Platform Musters - SLIMOffshore Platform Musters - SLIM
Risk Matrix
Human ErrorProbabilities
ConsequenceTable
Risk ReductionMeasures (IS)
9. Incident Investigation9. Incident Investigation
..
Team Planning
Incident
Loss
Notification to Activate Team
On-Site Investigation
Identification of Immediate Causes
Identification of Basic Causes
Lack of Management Control Factors
Recommendations
Implement Recommendations
Follow-Up
Inherent SafetyGuidewords
Inherent Safety Checklist
Inherent SafetyGuidewords
• People• Property• Production• Environment
• Position• People• Parts• Paper
• Immediate/ Technical• Avoid Hazards• Improve Management System
Remaining PSM ElementsRemaining PSM Elements
6. Process and Equipment Integrity6. Process and Equipment Integrity– Preventative maintenance (IS implications of Preventative maintenance (IS implications of
RBIM)RBIM)– Maintenance procedures (IS implications)Maintenance procedures (IS implications)
8. Training and Performance8. Training and Performance– IS needs analysis (e.g. incident investigation IS needs analysis (e.g. incident investigation
reports)reports)– IS learning objectives (measurable action IS learning objectives (measurable action
verbs)verbs)– IS resources (e.g. US CSB reports, AIChE, IS resources (e.g. US CSB reports, AIChE,
IChemE)IChemE)
Remaining PSM ElementsRemaining PSM Elements
10. Company Standards, Codes and 10. Company Standards, Codes and Regulations Regulations
– External/Internal (IS requirements)External/Internal (IS requirements)
11. Audits and Corrective Actions11. Audits and Corrective Actions– Evidence of commitment to IS usageEvidence of commitment to IS usage
12. Enhancement of Process Safety 12. Enhancement of Process Safety Knowledge Knowledge
– Include enhancement of IS knowledgeInclude enhancement of IS knowledge
CONCLUSIONCONCLUSION
Inherent SafetyInherent Safety is an integral component is an integral component of effective PSM.of effective PSM.Inherent SafetyInherent Safety is a common thread is a common thread throughout PSM elements.throughout PSM elements.Inherent SafetyInherent Safety is, however, an implicit is, however, an implicit consideration in PSM documentation.consideration in PSM documentation.Examples and methodologies – qualitative Examples and methodologies – qualitative and quantitative; new and existing – are and quantitative; new and existing – are available to make available to make Inherent SafetyInherent Safety an an explicit part of PSM.explicit part of PSM.
ACKNOWLDEGEMENTSACKNOWLDEGEMENTS
Natural Sciences and Engineering Natural Sciences and Engineering Research Council of CanadaResearch Council of Canada– Financial assistanceFinancial assistance
Canadian Chemical Producers’ Canadian Chemical Producers’ AssociationAssociation– PRIM data and analysis resultsPRIM data and analysis results
Colleagues in the process safety Colleagues in the process safety communitycommunity– Technical advice and critique of researchTechnical advice and critique of research
With Thanks to DennisWith Thanks to Dennis
TO REDUCE HAZARDSTO REDUCE HAZARDSMAKE IT SMALLER OR CHANGE ITMAKE IT SMALLER OR CHANGE IT
SO NO ONE GETS HURTSO NO ONE GETS HURT