Process Safety Management

390 Pages·2015·5.869 MB·English

by  Sutton, Ian

Plant Design and
Operations
Plant Design and
Operations
Ian Sutton
AMSTERDAM(cid:129)BOSTON(cid:129)HEIDELBERG(cid:129)LONDON
NEWYORK(cid:129)OXFORD(cid:129)PARIS(cid:129)SANDIEGO
SANFRANCISCO(cid:129)SINGAPORE(cid:129)SYDNEY(cid:129)TOKYO
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CHAPTER
1
Operations
CHAPTER OUTLINE
Introduction................................................................................................................2
ProfessionalAdvice....................................................................................................3
Regulations,Standards,andGuidance.........................................................................4
Regulations....................................................................................................4
IndustryStandards.........................................................................................4
ISO...................................................................................................................5
ANSI.................................................................................................................5
GuidanceDocuments......................................................................................5
UnitsofMeasurement.................................................................................................5
RiskReduction...........................................................................................................6
RiskAnalysis.................................................................................................6
Quantification................................................................................................6
FlammableandCombustibleMaterials.........................................................................7
FlammableRange...........................................................................................7
FlammableLimits..........................................................................................7
FlashPoint....................................................................................................7
CombustibleLiquids.......................................................................................8
ClassIIliquids...................................................................................................9
ClassIIIliquids..................................................................................................9
FlammableLiquids.........................................................................................9
IgnitionSources...........................................................................................10
AreaClassification....................................................................................................11
Housekeeping...........................................................................................................12
GeneralNeatness.........................................................................................12
ProperPlacement.........................................................................................13
GrassandBrush...........................................................................................13
EquipmentandPiping..................................................................................13
StorageandHandlingofFlammableLiquids...................................................13
Regulationsandstandards.............................................................................14
Handlingrequirements...................................................................................14
NonprocessOperations..............................................................................................15
OutsideStorage............................................................................................15
CoalandCokeStorage..................................................................................15
DrumStorage...............................................................................................16
1
PlantDesignandOperations.DOI:http://dx.doi.org/10.1016/B978-0-323-29964-0.00001-9
©2015ElsevierInc.Allrightsreserved.
2 CHAPTER 1 Operations
Drainage......................................................................................................16
FireProtectionandPrevention.......................................................................16
Cylinders.....................................................................................................16
LoadingRacks.............................................................................................17
SimultaneousOperations...........................................................................................18
ManagingSIMOPs........................................................................................19
SIMOPsMatrix.............................................................................................19
ConductingtheSIMOPs................................................................................20
Kickoffmeeting..............................................................................................20
Communicationmeetings...............................................................................21
Closeout......................................................................................................22
Examples..................................................................................................................22
Example1—FacilityDesign...........................................................................22
Example2—HeatExchanger.........................................................................23
INTRODUCTION
The purpose of this book is to provide practical guidance on issues to do with the
design, operation and maintenance of process facilities, including chemical plants,
oil refineries, offshore facilities and pipelines—with a focus on safety issues. It is
organized into the following chapters:
Chapter 1 Operations
Chapter 2 Maintenance andInspection
Chapter 3 Energy ControlProcedures
Chapter 4 Occupational Safety
Chapter 5 Chemicals
Chapter 6 Personal Protective Equipment
Chapter 7 Health andIndustrial Hygiene
Chapter 8 Human Factors and Ergonomics
Chapter 9 Firefighting
Chapter 10 Safety inDesign
Chapter 11 Siting and Layout
Chapter 12 Equipment
Chapter 13 Piping andValves
Chapter 14 Safety Instrumentation
Chapter 15 Transportation
Chapter 16 Security
Chapter 17 Common Hazards
This book is one in a series to do with the management of process facilities,
both onshore and offshore. Other titles include Process Risk and Reliability
Professional advice 3
Management (PRRM) and Offshore Safety Management. There is a particularly
strong overlap between the contents of this book and those of PRRM which dis-
cusses the process safety management systems that lie behind much of what is
written here. For example, this book’s Chapter 9 (Firefighting) is tightly inte-
grated with Chapter 12 (Emergency Management) of PRRM. Another example is
to do with the topic of Inherent Safety, the principles of which are discussed in
PRRM. This book shows how those principles are applied to design of equipment
such aspressure safety reliefvalves,tanks, and stairways.
The table ofcontentsfor PRRM is shown asfollows:
Chapter1—Risk Management
Chapter2—Compliance andStandards
Chapter3—Culture and Participation
Chapter4—Technical Information
Chapter5—Hazard Identification
Chapter6—Operating Procedures
Chapter7—Training and Competence
Chapter8—Prestartup Reviews
Chapter9—Asset Integrity
Chapter10—Management ofChange
Chapter11—Incident Investigationand RootCause Analysis
Chapter12—EmergencyManagement
Chapter13—Audits andAssessments
Chapter14—Consequence Analysis
Chapter15—Frequency Analysis
Chapter16—Reliability,Availability, andMaintainability
Chapter17—Managinga Risk Program
Chapter18—Project Management
Chapter19—Contractors
Chapter20—TheRisk Management Professional
PROFESSIONAL ADVICE
Thisbookcoversawiderangeofprofessionaltopicssuchashealth,humanfactors,andequipment
design.Itgoeswithoutsayingthataproperlyqualifiedprofessionalshouldbeconsultedfor
specificadviceinspecializedareassuchasthese.
Note:Thisbookalsodescribessomeoftheregulationstodowithsafety,designandoperations.
However,becauseeachcountryhasitsownlegalsystemandregulatoryinterpretationsareconstantly
changing,qualifiedlegaladviceshouldalwaysbeobtainedforeachparticularsystemandlocation.
4 CHAPTER 1 Operations
REGULATIONS, STANDARDS, AND GUIDANCE
The design and operation of process facilities is covered by a wide range of regu-
lations, industry consensus standards, and guidance documents such as books,
company standards, and manufacturer’s information. Many of these documents
are referred to and described in this book. The guidance provided here is general
in nature; each company and facility should use the material provided as a basis
for developingits own standards.
REGULATIONS
As the name implies, regulations must be followed—they are the law of the land.
Theycan benational/federal, state/province, orlocal.
In the United States, many of the regulations to do with the safety of process
facilities are written and enforced by the Occupational Health and Safety
Administration (OSHA). It is often found that OSHA’s rules and the interpreta-
tion of those rules are used internationally, even when there is no legal require-
ment to do so. The U.K. Health and Safety Executive (HSE) is another regulatory
agency whose influence often extends beyond itsown immediate jurisdiction.
Information as to how regulations are developed and enforced is provided in
Chapter 2of PRRM.
INDUSTRY STANDARDS
The International Organization for Standardization (ISO) defines a standard as a
documented agreement containing technical specifications or other precise criteria
to be used consistently as rules, guidelines, or definitions of characteristics, to
ensurethat materials, products, processes, andservices are fitfor their purposes.
In the process industries, consensus standards are published by bodies such as
the American Petroleum Institute (API), the National Fire Protection Association
(NFPA), and the American Society of Safety Engineers (ASSE). Generally, the
standards are written by industry experts who pool their knowledge and experi-
ence while working together on acommittee.
ISO also states that standards are developed according to the following
principles:
(cid:129) Consensus
(cid:129) Theviews ofall interestsare taken intoaccount: manufacturers, vendorsand
users, consumer groups, testing laboratories, governments, engineering
professions, andresearch organizations.
(cid:129) Industry-wide
(cid:129) Global solutions tosatisfy industries and customers worldwide
Units of measurement 5
Althoughcompliancewithindustrystandardsisusuallyvoluntary,manyofthem—
suchastheAPI’sRecommendedPractice14C—havebeenincorporatedintolaw.
Two organizations, ISO and the American National Standards Institute
(ANSI),help with the development and implementation ofstandards.
ISO
The International Organization for Standardization (ISO) has developed over 17,500
International Standards on a variety of subjects; some 1,100 new ISO standards are
published every year. Two groups of standards—ISO 9000 (Quality Management
Systems) and ISO 14000 (Environmental Management Systems)—are of particular
relevancetotheprocessindustries.
The manner in which an organization implements and manages its ISO 9000/
14000 programs is built aroundthe following four steps:
1. It writes down whatit is going to do.
2. It trains everybody tofollow the standards that have been set.
3. It implements an auditprogram.
4. It suggests meansfor improvingthe present operation.
ANSI
The ANSI has an accredited Standards Developing Organization. This organiza-
tion reviews procedures for writing standards in many of the standards bodies.
For example, ANSI will review and accept the manner in which an organization
resolves differences of opinion during the consensus phase of writing a new or
revised standard.
GUIDANCE DOCUMENTS
Many companies write internal standards for their own use. Such guidance often
reflects that company’s knowledge of unique issues, such as the handling of a
specialized chemical. These internal standards supplement the pertinent regula-
tions andindustry standards.
Guidance can also come from manufacturers and vendors. They know their
own equipment or products very well indeed and can often provide excellent
advicetodo with operations andsafety.
UNITS OF MEASUREMENT
The units of measurement used in this book are normally SI (Le Syste`me
International d’Unite´s, OI, 2006). However, many industrial standards have been
developed by companies working with the traditional English/American units
(sometimes referred to as customary units), and these are sometimes quoted here.
Also, many of the standards that are currently in use are clearly based on the
6 CHAPTER 1 Operations
traditional units. For example, flash points are defined with the round number of
100(cid:1)F (Fahrenheit). This converts tothe more awkward37.8(cid:1)C.
RISK REDUCTION
The management or risk is central to much of what is written in this book.
Decisions to do with topics as varied as vessel entry, the design of fire hydrants
and the selection of process chemicals all require an understanding of the risks
involved.
RISK ANALYSIS
The topics of risk analysis and risk management are discussed in depth in PRRM.
Equation (1.1) shows the three keyelements ofrisk:
Risk 5Consequence(cid:3)PredictedFrequency (1.1)
Hazard
Equation (1.1) shows that risk can never be zero—a truth not always grasped
by members of the general public or the news media. Hazards are always present
within all industrial facilities. Those hazards always have undesirable conse-
quences, andtheir likelihood ofoccurrence is always finite.
In general, the best way to reduce risk is to remove the hazard either by
eliminating the item that is causing the risk or by removing persons from the
scene of potential incidents. These approaches are summarized in the aphor-
isms, “If a tank’s not there, it can’t leak” and “If a man’s not there, he can’t be
killed.”
If the hazard cannot be removed, the next best step is usually to reduce the
consequence of the event. If that cannot be done, then the likelihood or predicted
frequency should be reduced. The final and least satisfactory step is to add safe-
guards such as safety instrumentation or personal protective equipment (PPE) for
the workers.
QUANTIFICATION
The importance of quantification is pointed out in two well-known quotations.
The first, attributed to Peter Drucker, is “What gets measured gets done”. The
second, attributed to W. Edwards Deming, is “In God we trust, all others must
bring data.” Those managing process facilities should follow the advice of these
two industry leaders. All decisions to do with operations, design, and safety
should beanalyzed quantitatively, whereverpossible.
Flammable and combustible materials 7
FLAMMABLE AND COMBUSTIBLE MATERIALS
Thisbookcontainsmanydiscussionstodowiththe controlofflammable and com-
bustiblematerials.Theterminologyusedforthistopic—whichcanbeconfusing—is
explainedinthefollowingsections.
FLAMMABLE RANGE
Firesrequirethe presence offuel andair(oxygen)alongwith asourceofignition.
These criteria are often referred toas the fire triangle.
The fuel has always to be in the form of a vapor (liquids and solids do not
burn directly—the fire generates flammable vapors at their surface and it is the
vapors that actually burn). Moreover, not all fuel vapor/oxygen mixtures will
burn—the concentrations have to lie inside the flammable range, which have
upper and lower limits for the concentrations of the fuel in the vapor space. The
flammability limits vary according to many factors, of which some of the most
important are the pressure and temperature of the mixture and the presence of
inert components such assteam,carbon dioxide, or nitrogen.
FLAMMABLE LIMITS
The flammable range for a fuel is defined by the lower flammable limit (LFL)
and the upper flammable limit (UFL). These terms are also referred to as the
upper and lower explosive limits. Below the LFL, there is insufficient flammable
material for a fire to occur—the mixture is “too lean.” It is the lowest concentra-
tion of a flammable vapor in air capable of producing a fire in the presence of an
ignition source.
The UFL is similar to the LFL except that there is too high a concentration of
vapor for afire tooccur—the mixture is said tobe “too rich.”
For most flammable hydrocarbons, the LFL is around 2%(cid:4)5%. For simple
alkanes, such as methane and ethane, the UFL is in the 10%(cid:4)15% range. Some
chemicals, such as hydrogen, ethylene oxide, and acetylene, have much higher
values for UFL. Values for flammable limit ranges for many flammable materials
are provided by NFPA 704—Standard System for the Identification of the
Hazards ofMaterialsfor Emergency Response.
FLASH POINT
The flash point of a flammable material is defined as the temperature at which a
vapor that is inside its flammable range that can be ignited. An ignition source
such as a flame or spark is needed to make the material actually burn. It is impor-
tant to recognize that an ignition source is required. The flash point is not the
same asthe autoignitiontemperature (AIT).