2-CCPS中国安全领导力和管理培训之操作程序.ppt

1、Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Operations Operating Procedures,Written document that provides the following: The steps needed to perform a task The order in which those steps are to be performed (if important) Any unique warnings or

2、cautions associated with a particular step,Purpose of Operating Procedures,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Where You Need Operating Procedures,Operating procedures should address the following scenarios for the production unit . and w

3、here complexity and/or criticality warrant, the same scenarios as above for individual pieces of equipment - e.g. compressors, reactors, etc),Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Initial startup Temporary operations Normal shutdown Emergen

4、cy shutdown Normal operation Emergency operations Startup after turnaround or emergency shutdown,Why Is It Important?,Without written operating procedures, a facility can have no assurance that the intended procedures and methods are performed in same manner and same sequence by: each different oper

5、ator each time by same operator,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Procedures must be concise and without ambiguity Information intended for education on chemistry, general hazards, why tasks are performed in a certain order etc. should

6、be placed in training documents,Content of Procedures,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Procedures Are NOT Training Documents,All procedures are not of same level of criticality/importance Consider an airliner Take-off and Landing Proce

7、dures Sequence for Re-Start of In-flight Entertainment System Guidelines for Storage of Oversize Passenger Bags,Risk Ranking of Procedures,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,When Procedure is . High consequence of deviation High complexi

8、ty Low-Moderate consequence Low-Moderate complexity Negligible consequence Low complexity,Tier Procedures by Risk Ranking,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Use . Checklist format. In-hand when performing task. Steps initialled. Written

9、format, but required in-hand when performing task Written format. Place in procedure manual for reference only,Certification of Procedures - When,Certification should be done before procedure is used for first time Recertify after any modification, and/or after an established time period,Copyright 2

10、011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Certification of Procedures,Certification should be done by field observation that the procedure can be followed . in the sequence provided without need for steps/actions not provided in the procedure,Copyright 20

11、11 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Port Neal IA - 1994,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,What Happened,Explosion in NH4NO3 plant in neutralizer and rundown vessels as a result of acidic

12、 conditions and high temperatures (200 psig steam for sparging) 4 Fatalities, 18 injured Release of 5700t of NH3 and 25,000gal HNO3,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Contributing Causes,Lack of written operating procedures Lack of train

13、ing on new DCS system No PHA conducted Poor mechanical integrity program,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Discussion Question,How is “Correctness “ of a procedure certified in your facility ? Is it adequate ?,Copyright 2011 Center for

14、Chemical Process Safety of the American Institute of Chemical Engineers,Manage Risk,Training And Performance Assurance,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chem

15、ical Engineers,Operations Training and Performance Assurance,Training/Performance Assurance,Training Instruction in job and task requirements, methods, and hazards if not done as instructed Performance Assurance (Certification) The means by which workers demonstrate that they understood and retained

16、 the training, and can apply it correctly in real-time job situations,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Why Is It Important?,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Training and

17、Performance Assurance is the only means by which a facility can be certain that an individual . . understands the safe and expected procedure for performing a task . understands the consequences of deviation from the expected procedure . is physically and mentally capable of performing the task in t

18、he field consistent with the training,Feyzin, France - 1966,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,What Happened,Major explosions and BLEVEs at LPG refinery 18 fatalities, 81 injured Release occurred when operator was draining water from bot

19、tom of a sphere Ignition by automobile on nearby motorway,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,What Happened,Samples from bottom of sphere routinely taken so bottom had to be drained prior to sampling Bottom of tank had two 2-inch plug val

20、ves with a -inch bleed valve between Drain line heated by steam tracing beneath insulation Procedure called for opening valve closest to vessel and then cracking open the bleed valve and adjust drawoff rate Operator opened the farthest valve from tank and then tried to open the closest valve to tank

21、. Discharge occurred after an ice plug blew out Operator tried to shut off flow but was unsuccessful Didnt use telephone in area because of ignition concerns and didnt drive away but walked 800m to control room,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical E

22、ngineers,Contributing Causes,The initial loss of containment Lack of operator training The Ignition and Inability to Protect the Spheres No means to control traffic on the motorway (distance to motorway 42m) Poor communication systems between field and control room Delay of firefighting and insuffic

23、ient water supply,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Training Requirements,Training, with Certification, should be provided to all personnel responsible for operating the facility: Initial training (before operating the process) Refreshe

24、r training (at least every 3 years. Critical tasks on shorter cycle) As part of the MOC for a process/equipment modification (when warranted by the complexity of the change) Training and Certification should be documented.,Copyright 2011 Center for Chemical Process Safety of the American Institute o

25、f Chemical Engineers,Certification / Performance Assurance,Testing for Retention of Knowledge and Ability to Correctly Perform a Task Allow several days between the instruction on a task, and the testing of performance on the task The “trainer” and the “tester” should be different individuals Physic

26、al ability to perform the task, as well as ability to perform the task in real-life plant environment (noise, heat, stress) should also be part of certification criteria,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Questions,How do you train emplo

27、yees in your company? What is a “passing” grade? How do you document the training? Do you refresh training just before a shut down or start up? How do you get employee feedback? What do you do with it?,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,

28、Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Operations Safe Work Practices,Safe Work Practices,Safe work practices help control hazards and manage non-routine work A non-routine activity is any activity that is not fully described in an operating

29、 procedure Safe work practices typically control hot work, stored energy (lockout/tag out), opening process vessels or lines, confined space entry, and similar hazardous operations,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Why Is It Important?,

30、The infrequency of non-routine work increases risk of error and/or inability to recognize a hazard. These errors or failure to recognize a hazard can lead to catastrophic events. Piper Alpha (removal of a pressure safety valve for recertification) Nitrogen asphyxiation during confined space entry re

31、sulted in 80 fatalities in U.S. from 1992-2002,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Piper Alpha - 1988,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Hot Work Permit Fire prevention and pr

32、otection requirements Line Break Permit Worker exposure and spill/release protection Confined Space Entry Permit Suitable atmospheres and collapse protection systems Energy/Electrical Lock outLock, Tag, & Try Unexpected presence or release of energy,Safe Work Practices - Examples,Copyright 2011 Cent

33、er for Chemical Process Safety of the American Institute of Chemical Engineers,Discussion Questions,Name the Management Systems that Failed at Piper Alpha Would the Systems Used at Your Facility Have Prevented Piper Alpha? If Yes, How?,Copyright 2011 Center for Chemical Process Safety of the America

34、n Institute of Chemical Engineers,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Operations Asset Integrity and Reliability,Asset Integrity and Reliability,The systematic implementation of activities, such as inspections and tests necessary to ensur

35、e equipment will be suitable for its intended application through out its life Specifically, work activities focused on: Preventing catastrophic release of a hazardous material or sudden release of energy and Ensuring high availability or (dependability) of critical safety or utility systems that pr

36、event or mitigate the effects of these types of events,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Why Is It Important?,Designing and maintaining equipment fit for its purpose and functions when needed is of paramount importance Maintaining conta

37、inment of hazardous materials and ensuring that safety systems work when needed are two primary responsibilities for any facility,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Asset Integrity and Reliability,Written procedures should be developed a

38、nd implemented to maintain the mechanical integrity of equipment including: Pressure vessels and storage tanks Piping systems Relief and vent systems Emergency shutdown systems Controls, alarms, sensors, and interlocks Pumps,Copyright 2011 Center for Chemical Process Safety of the American Institute

39、 of Chemical Engineers,Asset Integrity Programs,Asset Integrity Programs should address: Written procedures Training for maintenance activities Overview of process and its hazards Safety procedures applicable to the employees job Craft skills Inspection and testing Frequency consistent with recommen

40、dations and findings Generally accepted good engineering practices/standards Documentation of findings and actions taken,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Asset Integrity Programs,Asset Integrity Programs should address: Operating Limit

41、s Correcting Deficiencies Before further use In a safe and timely manner when steps are taken to assure safe operation until permanent corrections can be made Quality Assurance Program Fabrication, Installation, and spare partssuitable for service,Copyright 2011 Center for Chemical Process Safety of

42、 the American Institute of Chemical Engineers,Asset Integrity A system to assure equipment is suitable for its intended application throughout its life Mechanical Integrity A system to assure that equipment used to process, store, or handle HHCs is designed, constructed, installed and maintained to

43、minimize the risk of releases of such chemicals Reliability The probability that an item will perform as expected (designed) when needed Mechanical Integrity and Reliability are not the same thing and are not necessarily equal Reliability is often much more than Mechanical Integrity,Asset Integrity,

44、 Mechanical Integrity and Reliability,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Written mechanical integrity procedures Inspection and testing in accordance with appropriate codes and standards PHA and incident investigation findings may requir

45、e changes in mechanical integrity procedures,Obligations And Expectations,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Discussion Questions,Have you defined your MI “process safety critical equipment”? How is maintenance training handled? Have you

46、 defined acceptable operating limits for equipment? Do you have a quality program for materials received?,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,DuPont Belle W.Va., 23 Jan 2010,Background Phosgene supplied to facility in 1 ton cylinders Phos

47、gene both stored and connected to process from a semi enclosed shed Used as raw material in manufacture of 5 isocyanurate intermediates,Phosgene Shed,What Happened,Phosgene flex transfer hose connected to partially filled, but not in service 1 ton cylinder failed catastrophically 1 worker, who happe

48、ned to be near the site of release, was exposed to the phosgene and subsequently died,Why it Happened,Flex hose constructed of PTFE lined 304SS which is susceptible to corrosion Knowledge of better hose material known previously and communicated but not acted upon Changeout and replacement of hoses

49、required on a monthly basis but not followed Non routine operations on day of incident resulted in phosgene left isolated in hose which resulted in thermal expansion,Phosgene Flex Hoses,Hose Changeout Frequency,Asset Integrity Contributing Factors,Maintenance model of SAP used to issue work orders f

50、or monthly hose changeouts In late 2005 data managing the changeout frequency was modified and WOs no longer issued No MOC applied to the change No backup protection such as critical maintenance checklists or inspection tags Supervisors relied on maintenance coordinator to remember changeout,Other C

51、ontributing Factors,PHAs deficient corrosion of hoses and liquid expansion in hoses not addressed A 1988 risk analysis identified need for enclosure of shed to minimize primarily off site risk. Options were evaluated but no actions taken. In 2004 a PHA recommended enclosure no action taken Internal

52、Phosgene Committee audit observed hoses had moderate external corrosion but did not provide a recommendation. HTM manual guidance only, not a standard Operators unaware of hazards of thermal expansion of liquids Near miss on morning shift the day of incident not addressed Deficiencies in emergency r

53、esponse,Critique,Have you changed your MMS recently? What steps have you taken to ensure all critical testing is entered successfully into the new system? How robust is your MOC process with respect to your MMS? What other safeguards do you employ with respect to ensuring critical safety equipment i

54、s maintained, tested and changed out on the designated basis?,Asset Integrity and Reliability,Principles Identify equipment and systems that are within the scope of the asset integrity program and assign inspection, testing, and preventative maintenance (ITPM) task Develop and maintain knowledge, sk

55、ills procedures, and tools Ensure continued fitness for purpose Analyze equipment failures and deficiencies Analyze data,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Discussion Question,Your plant has a turnaround every 3 years Process relief valv

56、es are tested Management wants to extend the time for turnaround by an additional 18 months This will result in a deviation from the established procedure What do you do now when this situation develops? What could be done to assure the risk is not unacceptable to management?,Copyright 2011 Center f

57、or Chemical Process Safety of the American Institute of Chemical Engineers,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Operations Contractor Safety Management,Contractor (Safety) Management,System of controls to ensure Contracted services support

58、 both facility operations and the companys process safety and personal safety performance goals Does not address The procurement of goods and supplies or offsite equipment fabrication functions that are covered by the asset integrity quality assurance function Involves workers located closest to pro

59、cess hazards and more routine tasks such as janitorial and ground keeping services,Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers,Why Is It Important?,Company can achieve goals: Access specialize expertise that is not continuously or routinely required Supplement limited company resources during periods of unusual demand Provide staff increases without the overhead cost of direct hire employees,Companies and contractors should work together to provide a safe workplace that protects the workforce, the community, and the environment,