Process Safety and Efficiency - downstream-asia.com€¦ · Process Safety and Efficiency Dinesh...

Process Safety and Efficiency

Dinesh Vaidya Reliance Industries Limited

Nagothane Manufacturing Division 28th and 29th October 2015

DISCLAIMER

Any statement, opinion, prediction, comment, or observation made in this

presentation/publication are those of the presenter/author only and in no condition should be

construed necessarily representing the policy and intent of Reliance Industries Ltd. (RIL).

The information presented herein are of the presenter/author’s own and in no way RIL

attracts any liability for any inconsistency or irregularity in terms of the accuracy

completeness, veracity, or truth of the content of the presentation/publication. In addition,

RIL shall not be liable for any copyright infringement and misrepresentation for the

presented content as the content is presumed in good faith to be a creation of

presenter’s/author’s own mind.

The scope of this presentation/publication is strictly for knowledge sharing purposes and

not necessarily to provide any advice or recommendation to the audience/readers. Any

endorsement, recommendation, suggestion, or advice made by the presenter/author shall be

in his personal capacity and not in professional capacity as an employee of RIL. Any person

acting on such endorsement, recommendation, suggestion, or advice will himself/herself be

responsible for any injury/damage.

© Reliance Industries Ltd., 2015

Dhirubhai H. Ambani Founder Chairman Reliance Group

• 1966- Establishes Textile mill in Naroda

• 1977- Public share offering Raised money from

public offerings oversubscribed 7X

• 1982- Builds fiber/filament plant in Patalganga

• 1995- Builds Polyolefin plants at Hazira

• 1997- Builds multi-feed cracker at Hazira

• 1999- Builds Jamnagar refinery

• 2002- Acquired IPCL a state run company

• 2008- Builds JERP refinery at Jamnagar

• 2009- Begins KG D6 gas production

• 2013- Builds PBR/SBR plants at Hazira

• 2014- Builds PTA plant at Dahej

• 2014- Builds PET plant at Dahej

RIL - BRIEF INTRODUCTION


• 'zero harm',

• 'flawless operation',

• 'target zero',

• 'incident free',

• nobody gets hurt';

Key words in industries !


http://www.fastcodesign.com/3021307/innovation-by-design/why-facebooks-new-like-button-had-to-ditch-the-thumbs-up

• How likely am I to have an incident-free

day tomorrow?"

• How do you know it won't happen to

you?

• How will we assure the integrity of the

operation?

• How will we know we are doing it?

Questions to ask ..


Productivity of any facility drops immediately to zero

if, ..

• It blows up

• Burns down

• Sever impact on Community

• Shutdown for violation of regulations.

ZEROth LAW OF ASSET PRODUCTIVITY


Why we need PSM ?

• Bhopal, India (1984) – 3,000 deaths

Isocyanate release • BP Texas , Refinery (2005)

– 15 deaths, 170 injuries Petroleum explosion

• Cincinnati, OH (1990) – 2 deaths

Explosion • Sterlington, LA (1991)

– 8 deaths, 128 injuries Chemical release


The worst accident in the history of chemical industry occurred on

3rd Dec 1984.

25 MT of MIC leaked from storage tank killing about 3000

people.

MIC got contaminated with water & a runaway reaction occurred.

BHOPAL INCIDENT


On 23rd Mar 2005, a major explosion in the refinery claimed 15 lives & over 170 injured. Loss to the Company: - $ 700 million for compensation to victims - $1000 million pledged for safety improvement - $ 21.3 million fine imposed by OSHA Incident During ISOM unit start-up, Naphtha splitter column hot material overflowed into blow down drum and further spilled

BP TEXAS REFINERY


https://www.google.co.in/url?sa=i&rct=j&q=&esrc=s&frm=1&source=images&cd=&cad=rja&uact=8&ved=0CAcQjRxqFQoTCIaN7f2Sq8gCFRJtjgodYwgGcw&url=https%3A%2F%2Fen.wikipedia.org%2Fwiki%2FTexas_City_Refinery_explosion&psig=AFQjCNFMHdQ94AZda8QfcUM-BJ6dnxON6Q&ust=1444128213520433

Deaths ( approx) Injuries

• 1984 Mexico City 650 --

• 1984 Bhopal, India 3000 --

• 1984 Chicago area 17 17

• 1985 West Virginia -- 135

• 1988 New Orleans 5 23

• 1988 Henderson, NV 2 350

• 1989 Pasadena, TX 23 130

• 1990 Houston, TX 17 --

• 1990 Cincinnati, OH 2 72

• 1991 Lake Charles, LA 5 --

• 1991 Sterlington, LA 8 120

• 1991 Charleston, SC 6 33

Catastrophic Events


The three protective systems were out of order. The refrigeration system to cool the tank was shutdown. Scrubbing system to absorb vapor was not available. The flare system was out of use.

Why ?

The column bottom level indicator & high level alarms were faulty. Operators were not provided correct SOP. SOP was not updated after management of change was carried out on the column. SFE instructed the field operator to sign checklist without verifying the activities. Shift handover did not take place properly

Process Safety Management system failure !


What Is Process Safety Management (PSM)?

Process safety -

The operation of facilities that handle, use, process or store hazardous materials in a manner free from episodic or catastrophic incidents

PSM is defined as:

Application of management systems and controls (programs, procedures, audits, evaluations) to a manufacturing process in a way that process hazards are identified, understood, and controlled so that process related injuries and incidents are prevented.


"Process" means any activity involving a highly hazardous chemical including any use, storage, manufacturing, handling, or the on-site movement of such chemicals, or combination of these activities

PSM focuses on three key areas:

• Technology

• Facilities

• Personnel

What Is Process Safety Management (PSM)?


– Failures of PSM can result in infrequent or even rare but

catastrophic incidents with multiple injuries, fatalities and community and environmental impact.

– It is focused on the functioning of processes and systems (process hazards, mechanical integrity of systems etc.).

PSM and Workplace Safety


Professor Andrew Hopkins --personal safety and process safety. An important safety concern in the airline industry is injuries to baggage handlers from lifting and carrying – for example, back and muscle strains (personal safety). But no airline would ever think that their efforts to reduce these injuries would improve flight safety (equivalent to process safety). Different activities and programs are required to manage these different safety concerns.

Analogy Between Process Safety and Personal Safety


– Process incidents typically result from errors or conditions that can ultimately be traced to breakdowns in management control.

– Some examples of these errors or conditions:

• Inadequate understanding of process technology.

• Incomplete or obsolete operating or emergency procedures.

• Unauthorized or inadequately designed equipment or modifications.

• Inadequate inspection or maintenance programs.

• Inadequate job knowledge and/or training .

• Inadequate supervision.

• Failure to communicate the details of process technology.

Why PSM?


Process Safety and Risk Management Model


The process technology (PT) package provides a description of the process. It provides the foundation for identifying and understanding the hazards involved-the first steps in the process safety management effort.

The PT package generally consists of three parts: • Hazards of materials

• Process design basis

• Equipment design basis

• Block flow or process flow diagram

• Process chemistry

• Maximum intended inventory

• Materials of construction

• P&IDs

• Electrical Classification

• Relief system design & design basis

PROCESS TECHNOLOGY


Organized and systematic effort to identify and analyze the significance of potential hazards associated with the processing or handling of highly hazardous chemicals

“Process hazards analysis (PHA) is used to methodically identify, evaluate and develop methods to control significant hazards in the process. The completed PHA is used to follow up accepted recommendations and to communicate to affected personnel.”

PROCESS HAZARD ANALYSIS


Causes/consequences of fires & explosions

Releases of toxic or flammable chemicals

Major spills of hazardous chemicals

Methodology depends on the process & its characteristics

– What If?

– Checklist

– What If?/Checklist

– Hazard & Operability Study (HAZOP)

– Failure Mode & Effects Analysis (FMEA)

– Fault Tree Analysis (FTA)

PROCESS HAZARD ANALYSIS – Tools


Operating procedures provide a clear understanding of

parameters for safe operation for those who are operating the process. They also clearly explain the safety , health and environmental consequences of operation out side process limits and describe steps to be taken to correct and/or avoid deviations

• Initial startup, operation, shutdown

• Temporary & emergency operations, emergency shutdown

• Startup following shutdowns

• Consequences of deviations

• prevention of deviations

• Chemical properties and hazards

• Precautions to prevent exposure

• Control measures if contact or airborne exposure occurs

• Decommissioning / abdondoning of facility

OPERATING PROCEDURES AND SAFE PRACTICES


Changes to documented Process Technology potentially invalidate prior hazard assessments. Accordingly, all changes to the documented Process Technology are subjected to the same rigorous review that is applied to new processes

MANAGEMENT OF TECHNOLOGY CHANGE

• Hazards of chemicals

• Equipment design basis

• Process design Basis

• Everything except “replacement in kind”

• Temporary as well as permanent changes

• Technical basis for change

• Safety & health effects


Personnel involved in proposing or making process changes must understand the concept of “change” and what constitutes the following:

• A change outside the existing technology.

• A change within the existing technology.

• A replacement in kind.

• Modified operation procedures

• Time necessary for change

• Authorization for change

• Ways to inform & train workers before change

MANAGEMENT OF TECHNOLOGY CHANGE


• Design basis and criteria documented and communicated to vendor and operating/maintenance personnel

• Written quality control procedures addressing fabrication

• Appropriate checks and inspections to ensure that critical equipment is fabricated and installed consistent with design specifications

Efforts bridges the gap between design specifications and the initial installation.

Efforts help verify that process equipment meets the following standards:

1. Selection of Material of construction

2. Fabricated in accordance with design specifications.

3. Delivered to the proper location.

4. Assembled and installed properly

QUALITY ASSURANCE


The pre-startup safety review provides a final check of new and modified equipment to confirm that all appropriate elements of process safety have been addressed satisfactorily and the facility is safe to operate.

Done when:

• New processes

• Modified process

• Shutdown

• Equipment additions / deletion

– Recommendations Categorization and tracking

PRESTART-UP SAFETY REVIEWS


A comprehensive mechanical integrity program is necessary to ensure that the system integrity to contain hazardous materials is maintained from the time of initial installation throughout the life of the facility.

Availability – Functioning and Integrity

Includes the following features:

– Maintenance procedures

– Training and performance of personnel

– Quality control procedures

– Equipment tests and inspections, including predictive & preventive maintenance

– Repairs and changes

– Reliability engineering

MECHANICAL INTEGRITY


Changes to facilities within the documented technology (i.e. Process Safety Information) that are not replacement in kind, must receive appropriate review and authorization prior to implementation.

Management of subtle facility change

“ Any change within the documented technology, but which is not a replacement in kind ”

Management of change

Any change to the documented technology ,i.e., a change in hazards of materials, a change in the equipment design basis, or a change to the process design basis.

MANAGEMENT OF SUBTLE FACILITY CHANGE


Properly trained and performing personnel are a requirement for keeping process equipment and machinery operating safely. Employees must also be physically able, mentally alert, and capable of using good judgment to properly follow prescribed practices.

All other elements of PSRM can be in place but without properly trained and performing personnel, the chances of safe process operation are greatly diminished.

TRAINING AND PERFORMANCE


All tasks must be completed safely and performed in accordance with established procedures and/or safe work practices, consistent with the principles of good PSM, whether the tasks are completed by site personnel or by contract personnel.

–Certify the contractors in safe execution of their work

–Follow a six step method for contractor safety

–MRC and training

–No repeat violations are allowed

CONTRACTORS


Serious and serious potential incidents are likely to recur unless key factors are identified and corrected. Aggressive and persistent investigation of all serious and serious potential incidents is necessary to continuously improve safety performance

• Extent of the hazardous nature of the material released

• Quantity actually released

• Potential release qty.

• Degree of control exercised

• Functioning of safety devices during the incidence

• Actual on site impact

• Potential on site impact

• Actual offsite impact

• Potential offsite impact

• Monetary loss

INCIDENT INVESTIGATION


A minimum level of experience and knowledge is required of operating, maintenance and technical group assigned to a process area in order to provide a solid base for decision that affect process safety:

• Develop guidelines for maintaining minimum levels of experience and knowledge in the process groups

• Train newly assigned personnel in

Principles and features of process safety

PT for their process area

• Review proficiency of new personnel following training

• Provide additional measures if losses of experience and knowledge occur beyond local control

MANAGEMENT OF PERSONNEL CHANGE


In depth planning for potential emergencies is required so that effective response by the site with the community can mitigate the impact on people, the environment, and facilities.

– PDCA approach ERCP

– ERCP plans for maximum creditable loss scenarios

– Plant level emergency drills and testing

– Pipeline safety plans

– Legal compliance

– Review and closer of recommendations

– Updating ERCP standards

EMERGENCY PLANNING AND RESPONSE


• Audits are important tools in the establishment, measurement, maintenance, and continuous improvement of process safety performance. Audits compare performance versus established standards

– Guidelines

– Standards

– Protocols

– First/ Second / Third party audits

AUDITING


OD - WHAT IS IT?

Dedication and commitment by every member of the organization to carry out each task the right way every time.

OPERATING EXCELLENCE- WHAT IS IT?

Operating excellence results when an organization establishes OD and completes all tasks properly, thus contributing to the organization's goal of achieving business excellence.

ACHIEVING OPERATING EXCELLENCE THROUGH OPERATIONAL DISCIPLINE


Operation Excellence

Leadership by

Example Common Shared Values

Pride in the

Organization

Active lines of

communication

Practice consistent

with Procedure

Strong Teamwork

Sufficient and

Capable Resources

Employee Involveme

nt

Up-To-Date- Documentati

on

Absence of

Shortcut

Excellent

Housekeeping

OPERATION EXCELLENCE


Developing Safety Culture

Dependent

‘Zero is Unrealistic’

Independent

‘Zero by Chance’

Interdependent

‘Zero by Choice’

Management Commitment

Condition of Employment

Rules

Supervisory Control

Fear/Discipline

Personal Commitment

Self-Managing

Self-Discipline

Self-Responsibility

Personal Goals

Care for Self

Team Building

Team Commitment

Development in Team

Help Others Conform

Value for Each Other

Team Goals

Injuries


• How likely am I to have an incident-free day tomorrow?"

• How do you know it won't happen to you?

• How will we assure the integrity of the operation?

• How will we know we are doing it?

Process Safety and Efficiency - downstream-asia.com€¦ · Process Safety and Efficiency Dinesh...

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