Handbook on Process Safety Integrity for Utility Operators.pdfVIP专享VIP免费原创优质

1HandbookonProcessSafetyIntegrityforUtilityOperatorsAuthor:EurIngFarooqJanjua,CEng,BEng,MIChemE,MCIWEM,MIWMINPUBLICATIONJULY20142PrefaceThishandbookisintendedforutilityoperatorstoexplaintheprocesssafetyintegrityissueswiththefocusonmaintainingthelongtermsustainability,efficiencyandeffectivenessoftheutilityassets.Itishopedthishandbookprovidesthebasisoftheessentialsformanagersandkeyengineersresponsiblefortheownership,operationandmaintenanceofassetsintheutilitysectorManythanksFarooqJanjua,Riyadh,KSA,July2014Nothingissoimportantthatwecannottakethetimetodoitsafelyandproperly3TableofContentsSection1:Introduction……………………………………………………..4Section2:HazardIdentificationAnalysis……………………………..33Section3:CriticalAssetIdentification…………………………………58Section4:AssetIntegrityAssessment…………………………………76Section5:EmergencyResponsePlanning…………………………....91Section6:RiskReviewChecklists…………………………………………108References…………………………………………………………………………..1334SECTION1:INTRODUCTION1.1IntroductionAttheonsetthechallengesfacedbycommonprocessoperatorsistolowerOperationalRiskandimproveProductionEfficiencyor…istheKeytobetteroptimizehowwemanageoperationandmaintenanceworkloadagainstadevelopedriskmanagementpolicyTheaimofthisbookistoprovideanoverviewoftheholisticunderstandingofassessingandunderstandingoperationalrisksandtheneedforstandardization&systematizationofworkingpracticesforprioritizationofsafetyrelatedandproductioncriticalworkInconnectionwithlinkbetweenmanagementofassets,safetyandriskswhichisthethemeofthisbookthecommonlinkistheneedforaprocessplanttomaintainsafeandreliablesustainableoperationalperformanceThechallengeforexampleinoperatingageingassetsasacommonissueamongstutilityoperatorsistheneedfordependableequipment,competentpersonnelandeffectivesystems.SomequotationsregardingageingequipmentfromtheUKRegulator“Ageingisnotabouthowoldtheequipmentis.It’saboutwhatisknownaboutitscondition,andhowthat’schangingovertime”HSEResearchReportRR509-‘Theplantageingguide’“Ageingis…whereacomponentsuffersdeteriorationanddamage(usually,butnotnecessarily,associatedwithtimeinservice)withanincreasinglikelihoodoffailure….HSEResearchReportRR823-‘PlantAgeingStudy’Theunderlyingthemeofthisbookthereforeisasetoftencommonthemestowardsasustainableplanforassetandprocessintegrity1.Conductananalysiswithanapprovedassetmanagementintegrityperformanceinstrument(Data&KPICollection)2.DevelopaManagementControlReportingSystem(MCRS)3.Definethesystem,processes,peopleandentitiesevolvedprograms4.Developmentofdocumentation/processstandards5.Designandagreeaverificationprogram/process6.IdentificationofSafetyCriticalEquipmentandprocesses(SafetyCase,Bow-Tie,Hazid/op)7.Definemaintenance,testing,monitoring,inspections,andoperationsinvolvement8.RiskmanagementassuredthroughQA/QC(developmentofperformancestandards,assurancestandardsandmaintenancestrategies)9.Integrationofstandardsandspecificationswithtoolsandreporting10.Training&Coachingprogram-(KEYTOSUSTAINABILITY!)Someexamplesofsometypicalgeneralchallengesinachievingthismaybeasfollows:Dependableequipment:Equipmentprojectedasnotfitforpurpose,Increasedcongestionofequipmentandremovalofredundantequipment,replacementofobsoleteequipment,operationoutsideoriginaldesignorlackofturndowncapacity,reducingequipmenta...