design safety into your plant mary kay o’conner process safety symposium
DESCRIPTION
Design Safety into Your Plant Mary Kay O’Conner Process Safety Symposium. Frank Joop Global Business Development Intergraph Process, Power & Marine. Be Pro-active – “SAFETY FIRST”. Safety is at the Forefront. Was this your plant……………. The Basics. Risk Reduction - PowerPoint PPT PresentationTRANSCRIPT
Process, Power and Marine DivisionDesign Safety into Your PlantMary Kay O’Conner Process Safety Symposium
Frank JoopGlobal Business DevelopmentIntergraph Process, Power & Marine
Be Pro-active – “SAFETY FIRST”
Safety is at the Forefront
Was this your plant…………….
The Basics
Risk Reduction– Instrument are a well accepted risk reduction
system– Safety for personnel, facility and environment
Contributors to an accident– Course– Process deviation– What is released to the atmosphere
Risk Reduction
Increasing Risk
Process RiskTolerable RiskResidual Risk
Necessary Risk Reduction
Actual Risk Reduction (ALARP)
ProcessDesignBPCSAlarmsReliefSIS
Tolerable Risk
The Standards
ISA S84.01 and IEC 61508 Framework for the design Key steps are:
– Process design– HAZOP and Risk analysis– Determine protection layers– Define Safety Integrity Level (SIL)– Define SIS– Specification of SIS– Design– Operating procedures– Commissioning– Modification coupled back to the process design
Risk Assessment
What if Checklist What if/ Checklist
HAZOP FMECA FTA
Method Smaller system
For repeatable systems
For proven designs
For larger and more complex systems
For any type or size system
For any type or size system
Plus Fast and simple
Standardized approach
Good and fast method
Very thorough
Very thorough
Very thorough, with diagrams
Minus Not very thorough
No new analysis components
Need experienced personnel
Very time consuming
Very time consuming
More for individuals rather then a group approach which means less input from experience
HAZOP’s – What, Why and How?HAZOP’s – What, Why and How?
The best, most rigorous method for hazard assessment Team of 5 – 8 experienced engineers, operators Usually after the design / change is complete Impacts time TO market and time IN market
Hazard Identification
Likelihood vs. Severity
Risk reduction
Process Safety Information Systems
Design Control
Maintenance Finance
Safety
Process Safety is Mission CriticalProcess Safety is Mission Critical
Law License to operate
Cost Injury, plant damage Abnormal upsets
Image Staff Community Marketplace
HAZOP’s – What, Why and How?HAZOP’s – What, Why and How?
DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION
HAZOP = Hazard and Operability Studies Study of the possibility of deviation from the design intent HAZOP Fundamentals:
– Deviation– Course
Key words are:– Flow, Temperature, Pressure, Level, Separate (settle, filter, centrifuge),
Composition, React Mix, Reduce (grind, crush, etc.), Absorb, Corrode Erode
Operational words– Isolate, Drain, Vent, Purge, Inspect, Maintain, Start-up, Shutdown
Secondary Key Words– No, Less, More, Reverse, Also, Other, Fluctuation, Early, Late
HAZOP’s – What, Why and How?HAZOP’s – What, Why and How?
DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION
No, Flow StrainerBlockage
Pump cavitationsWrong mixing
Pressure measurementAt pumpInspection of filter
Add instr.
Verifying each system
Process Design Instrument design Piping layout Material ordering HAZOP
– Found error– Design change ($$)– Change order for material/equipment ($$$$$)
HAZOP’s late in the scheduleHAZOP’s late in the schedule
DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION
No, Flow StrainerBlockage
Pump cavitationsWrong mixing
Pressure measurementAt pumpInspection of filter
Add instr.
Impact / Follow on Effect:
- DCS Configuration- DCS HMI (Graphics)- Alarm Management- Asset Management- Instrumentation Design- Procurement Changes- Vendor Communications- Piping Changes- Material Changes- Construction Planning- Commissioning- Spare Parts Loading- Documentation- Etc...
Multiple by thousands of potential “Safe-guards”
HAZOP’s late in the scheduleHAZOP’s late in the schedule
HAZOP’s – Earlier in the scheduleHAZOP’s – Earlier in the schedule
Process Design Make HAZOP part of design process early on Instrument design Piping layout Material ordering HAZOP (final)
– No errors– No Design change– No Change order for material/equipment
Reduced design and CAPEX risks
SmartPlant Process Safety enables to design safety into your plant and
reduces the operational risks. Design = EPC Operational = OO
The Solution The Solution
SPPS Process Safety information
Hazop study
Knowledge base
Knowledge from experts, captured once only
Structured database
Full, auditable record
Comprehensive
Consistent
- Up to 50% time & cost reduction
P&IDsLessons learned
Plant safety information today
Hazop study
Maintenance Plant Modification
Operation
Lack of safety data impacts
Plant safety knowledge
The Solution
Equipment Models in SmartPlant Process Safety
Knowledge about the behaviour of process equipment is essential for hazard identification.
Each equipment type in SPPS has a “Model”.– Describes behaviour, failure modes and hazards.– Connects to other equipment through ports.– Models collected into a “Unit Model Library”.
“Instances” of these equipment models are used in the P&IDs which SPPS analyses.
The Solution
Flow Modelling…
Pin Pout
QoutQin
ToutTin
Pout
+
+
Pin
+
+
etc…
+
– ++ –
noQoutnoQin
Consequence:dry running
+
+
+
+
+ ++
+
+
Centrifugal pump:
The Solution
Plant Modelling…
The Solution
Equipment Models
The SolutionFault-consequence Lists…
The SolutionFault-consequence detail
The Solution
Fault-Consequence Assessment
MoC workflow
P&IDs Plant Safety database from SPPS and Hazop study
Existing plant
Proposed modification/new batch sheet
Modify P&IDs
Run SPPS to find
hazards
Engineering approval
Safety approval
Permit to work
Compare and Hazop new cause-consequences
Final approval
The Solution
Comparing before and after Hazops
The Solution
Any more F/C in this Node & deviation?
Brainstorming
HAZOP’s w/ SP Process SafetyHAZOP’s w/ SP Process SafetyTraditional HAZOP Study SP Process Safety HAZOP Study
Manually divide P&ID’s / Plantinto “nodes” to study and mark-upP&ID’s Manually prepare “node” work-sheet Focus on individual node and deviationat a time Manually work to identify fault-Consequence both inside and outside the node Manually identify and document safe-guards / instrumentation Assign actions and manually communicate them to respective disciplines Manually document study for future reference / audits
Automatically create “nodes” using intelligent data / rules from SmartPlant P&ID
Semi-Automatic preparation of “node” worksheet, interactive navigation and selection from P&ID database
Interactive visual aid to P&ID for brain storming activities
Automatic recommendations of Safe-Guards
Electronic and collaborative assignment of actions for respective disciplines
Automatic email-notification of actions, including action management functions
Automatically generate HAZOP reports / results
History management / comparison reports
Process Safety Integration Vision...
CORPORATE SAFETY
MEMORY
Data & Document
Management‘eEngineering
Integration Hub’
TE
FTE
F
TEF
TEF
TEF
SP- PID
SP3D
SPI
SPEL
TE
FT
EFTEF
BROWSER
TEF HAZOPS ACCIDENT DATA
MoC
SECURITY ACCIDENT INVESTIGATION
CALCULATIONS
HUMAN FACTORS
Business Results Achieved
Hazard
Identification
Automation
Risk
Assessment
Action
Management
Data
Handover
Early Hazard
Elimination
50% time & cost reduction Project schedule reduction
Consistent, thorough, Auditable Re-usable, comparable
Action validation
Unified record Faster re-hazops Better MoC Lessons learned
Safety of acquisitions
Build corporatesafety memory
(CSM)
Capture knowledge of experts once and re-use always
Check designsUsing CSM
Better design Make changes before limited, costly Shorter Hazop studies
Better action management
Visual aid to improve brainstorming
Summary
Full, auditable, consistent Hazops record
Reduced time, cost and tedium
Early design checking enables change before becomes costly, limited
Knowledge capture and use
– Company’s experts’ experience
– lessons learned
Hazop study results - living data
– Supporting MoC
– Accessible information
Process, Power and Marine Division
Integrating the Engineering Enterprise…