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Summary
Summary
First-line managers have to maintain the integrity of facilities, control manufacturing processes, and handle unusual or emergency situations, as well as respond to the pressures of production demand. On a daily basis, they are closest to the operating personnel who may be injured by a process accident, and they are in the best position to spot problem conditions and to act to contain them. This book offers these managers "how-to" information on process safety management program execution in the operations and maintenance departments, recommending technical and administrative process safety activities for the entire life cycle of the plant. Helpful tables and references add to the value of this process safety resource.
Author Notes
The CENTER FOR CHEMICAL PROCESS SAFETY (CCPS), an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has been a world leader in developing and disseminatinginformation on process safety management and technology since 1985. CCPS has published over 80 books in its process safety guidelines and process safety concepts series. For more information, visit www.ccpsonline.org.
Table of Contents
| Preface |
| Acknowledgments |
| List of Tables |
| List of Figures |
| Glossary |
| 1 Introduction |
| 1.1 Process Safety Management Activities of the Center for Chemical Process Safety (CCPS) |
| 1.2 Process Safety Activities of Governmental Agencies and Trade Organizations |
| 1.3 Target Audience and Objective of This Document |
| 1.4 Use of This Document |
| 1.5 References |
| 2 Role of Operations and Maintenance in Process Safety Management |
| 2.1 Accountability |
| 2.2 Process Knowledge and Documentation |
| 2.3 Capital Project Review and Design Procedures |
| 2.4 Process Risk Management |
| 2.5 Process and Equipment Integrity |
| 2.6 Human Factors |
| 2.7 Training and Performance |
| 2.8 Incident Investigation |
| 2.9 Standards, Codes, and Regulations |
| 2.10 Audits and Corrective Action |
| 2.11 Enhancement of Process Safety Knowledge |
| 2.12 Management of Change |
| 2.12.1 Importance of Changes |
| 2.12.2 Examples of Lessons To Be Learned from the Failure to Manage Change |
| 2.12.3 What Constitute Change? |
| 2.12.4 Process Change Authorization |
| 2.13 Summary |
| 2.14 References |
| 3 Plant Design |
| 3.1 Operations and Maintenance Departments' Roles |
| 3.2 Documentation |
| 3.3 Process Hazard Reviews |
| 3.4 Designing for Inherent Process Safety |
| 3.4.1 Process Fluids |
| 3.4.2 Inventory Minimization |
| 3.4.3 Operating and Storage Conditions |
| 3.5 Controlling of Hazards to Reduce Risks |
| 3.6 Plant Layout |
| 3.6.1 Site Planning |
| 3.6.2 Process Area Layout |
| 3.7 Plant Standards and Practices |
| 3.8 Human Factors in Plant Design |
| 3.9 Maintenance Considerations |
| 3.10 Management of Change |
| 3.11 References |
| 4 Plant Construction |
| 4.1 Roles of the Operations and Maintenance Department |
| 4.1.1 Communication and Coordination with Project Team |
| 4.1.2 Control of Specific Construction-Related Activities |
| 4.1.3 Inspection of Equipment Installation |
| 4.2 Materials of Construction |
| 4.3 Custom Equipment Fabrication and Inspection |
| 4.4 Field Installation |
| 4.4.1 Piping Installation |
| 4.4.2 Pressure-Relief/Vent Collection |
| 4.4.3 Other Safety Systems |
| 4.5 Equipment Recordkeeping |
| 4.6 Summary |
| 4.7 References |
| 5 Pre-Startup and Commissioning |
| 5.1 Organization and Roles |
| 5.1.1 Startup Team |
| 5.1.2 Role of Operations and Maintenance Departments |
| 5.2 Planning |
| 5.3 Preparation for Startup |
| 5.3.1 Staffing Operations and Maintenance Departments |
| 5.3.2 Training |
| 5.3.3 Maintenance Activities during Pre-startup |
| 5.3.4 Development of Operating Procedures |
| 5.4 Pre-startup Safety Review |
| 5.5 Commissioning |
| 5.5.1 Commissioning Utilities |
| 5.5.2 Commissioning Equipment |
| 5.5.3 Instruments, Computer, and Control |
| 5.6 Final Preparations for Startup |
| 5.7 References |
| 6 Startup |
| 6.1 Roles and Responsibilities |
| 6.2 Initial Startup |
| 6.2.1 Final Preparation |
| 6.2.2 Introduction of Process Chemicals and Materials |
| 6.2.3 Process and Process Equipment Monitoring |
| 6.2.4 Baseline Data |
| 6.2.5 Updating Startup Procedures |
| 6.3 Restart |
| 6.4 Startup after Turnaround |
| 6.5 Startup after Extended Outage |
| 6.6 Resources |
| 6.7 Summary |
| 6.8 References |
| 7 Operation |
| 7.1 Roles and Responsibilities |
| 7.2 Routine Operations |
| 7.2.1 Operating within Process and Equipment Limits |
| 7.2.2 Written Procedures |
| 7.2.3 Communication |
| 7.2.4 Communication During Shift Changes |
| 7.2.5 Special Safety Considerations of Batch Processes |
| 7.2.6 Process Control Software |
| 7.3 Nonroutine Operations |
| 7.3.1 Abnormal Operations |
| 7.3.2 Standby Operations |
| 7.4 Emergency Operations |
| 7.5 Management of Change |
| 7.6 Safety Protective Systems |
| 7.6.1 Safety Shutdown Systems |
| 7.6.2 Pressure Relief Equipment |
| 7.7 Operator Training |
| 7.7.1 Refre |
