Key focus areas in Chemical Process industry

Change and Equipment Management are key ELEMENTS in Process Safety System.

Some of the World’s “News splash incidents” have involved Change Management as focal point

Equipment Management is no less importantChange Management should follow appropriate Process Hazard Analysis CCPS is an excellent reference for proper

application of Process Hazard Evaluation Techniques

Hazard Evaluation TechniquesGuideline for Hazard Evaluation Procedure –Buy CCPS Book

Typical Techniques mentioned Safety review Checklists Relative Ranking Preliminary Hazard Analysis What –If , What-If checklist HAZOP FMEA FTA ETA CCA HRA

Change Management--Essentials

Change need driverCriteria for Change : SHE, IDLH, Life

threatening, Insurance, Legal, Statutory items should get priority attention

Change initiation procedure publicationPrescribing Change processing steps Determining Change review Team compositionValidating Change acceptance criteriaSign off protocol in Change approval checklist

Preceding Activity.

Change Planning should focus on PEMEChange organising should list -Preceding/Succeeding

activityChange control, MOC,Conformance to Codes,

Fabrication qualification , Inspection types-Source, Incoming,On-site, Material Spec, OEM Spec sheets,Deviation control/Approval are key aspects before Change implementation

Change validation should be tested by PDCA prior to Change confirmation as PermanentChange benefit evaluation is necessary

Succeeding Activities

Change revision ConfirmationSOP Revision. OSEP ReviewRe-trainingRe-certification of Trained personnelP.M. List UpdateIsometrics, P & ID, related Doc UpdateSpares Identification, Inventory stipulation

Contd..

Payout trackingArchiving database

Equipment Management—Book keeping

MOC Fabrication details, Related drawings, Isometrics Flanges, Gaskets, Nuts, Bolts, Piping, Bends, Elbows,

Fittings, Insulation-- Specifications Sheet FLP/IP/FRLS/HR /ZH/--DCS, PLC, SCADA Built-in Safety devices/features List of Codes/Standards adopted MTO Installation qualification Process/Operational qualification including HAZOP study Final qualification—ID, Asset entry, Insurance

Documentation/Maintenance

Deliverables Statutory SOP O &M Manuals OEM-Recommended Spares Spares Management kardex P.M. List/NDT Schedule Work instructions History card MTBF Charts

Performance Support Needs

List of Lubricants Supply Sources—Qualifications of Suppliers –Criteria AMC/Warranty Trade supports—Electrical, Instrumentation,

EHS,Engg Performance trending Run Log Inspection-Sensorial, Instrumentation (Speed, Vibration, Fatigue, Noise, Heat and such) NDT-Methodology, Monitoring Tools

Breakdown-Impact review aids

Incident log and reportsMacro InterruptionsMicro interruptionsRCA, Component reliability analysisRecovery Time Impact analysis—Economic/Customer impact Insurance Cover—Fire/Allied, Machinery Break

down, LOP, Natural/Security perils, Human contributory

Conclusion

Change involves thinking holisticallyChange may necessitate downtime Interruption due to incidents can affect safety of

personnel and Business economics.Each change review should be situation specific. General references cannot displace internal Multi-disciplinary review and validation.Yet changes can become necessary to continually

improve Safety, Health & Environment

Abbreviations List -AL

AMC Annual Maintenance Contract CCA Cause Consequence Analysis CCPS Centre for Chemical Process Safety DCS Distributed Control System EHS Environment, Health & Safety FLP Flameproof FMEA Failure Mode and Effects Analysis FRLS Fire Resistant Low Smoke HAZOP Hazard Operability HR Heat Resistant HRA Human Reliability Analysis IDLH Immediately Dangerous to Life & Health IP Ingress Protection LOP Loss of Profit

AL

MOC Material of Construction MTBF Mean Time Between Failure MTO Material Transfer Order NDT Non Destructive Testing O & M Operation & Maintenance OEM Original Equipment Manufacturer OSEP On Site Emergency Plan P & ID Piping & Instrumentation Diagram PDCA Plan Develop Check and Act PEME People, Environment, Materials, Equipment PHA Process Hazard Analysis PLC Programme Logic Controller PM Preventive Maintenance

AL

R & D Research & Development RCA Root Cause Analysis SCADA Supervisory Control and Data Acquisition SHE Safety, Health & Environment SOP Standard Operating Procedure ZH Zero Halogen

Source credits: Publications, Experiences,

Professional contributions,

Interactions with Chemical Industry,OEMs.