Preface... Acknowledgments... Glossary Introduction Management Systems and the Management of Chemical Process Safety...

Transcription

1 Preface... Acknowledgments... Glossary... xi xiii xv 1. Introduction Process Safety Management Activities of the Center for Chemical Process Safety (CCPS) Definition of "Process Safety Management" Scope Management Systems and the Management of Chemical Process Safety Introduction Management Systems for Chemical Process Safety Major Considerations for Developing and Implementing a Process Safety Management System... 8 Appendix 2A. Characteristics of a Management System Accountability: Objectives and Goals Overview Continuity of Operations Continuity of Systems Continuity of Organization Quality Process Control of Exceptions v

2 vi 3.7 Alternative Methods Management Accessibility Communications Company Expectations Appendix 3A. Example of the Management of Process Hazards Process Knowledge and Documentation Overview Chemical and Occupational Hazards Process Definition/Design Criteria Process and Equipment Design Protective Systems Normal and Upset Conditions Process Risk Management Decisions Company Memory (Management of Information) Appendix 4A. Example of a Typical Material Safety Data Sheet Appendix 4B. Lead Questions (Hazardous Conditions) Appendix 4C. Example of Process Definition/Design Criteria Appendix 4D. Examples of Typical Protective Systems/Equipment Data Appendix 4E. Example of Components Included in Process Knowledge and Documentation Process Safety Review Procedures for Capital Projects Overview Appropriation Request Procedures Hazard Reviews Sitting... 49

3 vii 5.5 Plot Plan Process Design and Review Procedures Project Management Procedures and Controls Appendix 5A. Plant Example of Organization of Process Hazard Review for Appropriation Requests Appendix 5B. Plant Example of Plant Procedures: "Description of Hazard Review for Appropriation Requests" Appendix 5C. Example of Plant Procedures for Appropriation Request Information and Approvals Appendix 5D. Plant Example of "Standard Practice for Process Reviews" Process Risk Management Overview Hazard Identification Risk Analysis of Operations Reduction of Risk Residual Risk Management Process Management during Emergencies Encouraging Client and Supplier Companies to Adopt Similar Risk Management Practices Selection of Businesses with Acceptable Risks Appendix 6A. Plant Example of Hazard Identification Appendix 6B. Plant "X" Risk Analysis of Operations Appendix 6C. Plant "Y" Risk Analysis of Operations Appendix 6D. Example of Process Management Used during Emergencies... 94

4 viii 7. Management of Change Overview Change of Process Technology Change of Facility Organizational Changes Variance Procedures Permanent Changes Temporary Changes Description of Examples Appendix 7A. Management of Change Policy Appendix 7B. Guideline for Review of Plant Changes or Modifications Appendix 7C. Control of Change Safety Management Practices Appendix 7D. Control of Changes Appendix 7E. Example of Change of Process Technology Appendix 7F. Example of Safety Assessment Form for Plant Modification Work Appendix 7G. Example of Management of Organization or Staffing Change Appendix 7H. Example of Variance Procedure and Variance Request Form Appendix 7I. Permanent Change Considerations Appendix 7J. Example of Jumpers/Bypasses Logging Process Equipment Integrity Overview Reliability Engineering Materials of Construction Fabrication and Inspection Procedures Installation Procedures

5 ix 8.6 Preventative Maintenance Process, Hardware and Systems Inspection and Testing Maintenance Procedures Alarm and Instrument Management Decommissioning and Demolition Procedures Appendix 8A. Example of Plant Management System for Materials of Construction (MOC) Appendix 8B. Example of Test and Inspection Equipment and Procedures Appendix 8C. Example of Field Inspection and Testing of Process Safety Systems Appendix 8D. Example of a Hot Work Permit Appendix 8E. Example of Criteria for Test and Inspection of Safety Relief Devices Appendix 8F Example of Management System for Critical and Unique Safety Features Appendix 8G. Table of from Chemical Manufacturers Association Fixed Equipment Inspection Guide Human Factors Overview Operator/Process and Operator/Equipment Interfaces Administrative Controls Versus Hardware Human Error Assessment Appendix 9A. Human Factors Considerations in Some of the Key Elements of Process Safety Management Training and Performance Overview Definition of Skills and Knowledge

6 x 10.3 Design of Operating and Maintenance Procedures Initial Qualifications Assessment Selection and Development of Training Program Measuring Performance and Effectiveness Instructor Program Records Management Ongoing Performance and Refresher Training Appendix 10A. Example of Operator Process Safety Training Program Appendix 10B. Example of Maintenance Training Program for Process Safety Appendix 10C. Example of Operations Technical Staff Training Program Appendix 10D. Example of Maintenance Training Implementation (Estimated Cost/Person) Appendix 10E. Example of Instructional Standards Appendix 10F. Example of Refresher Training Course Frequencies Incident Investigation Overview Major Incidents Third-Party Participation Follow-Up and Resolution Communication Incident Recording, Reporting, and Analysis Near Miss Reporting Appendix 11A. Example of Extraordinary Event Notification, Investigating, and Reporting Appendix 11B. Example of Plant Follow-Up Procedures for Accident/Incident Investigation Recommendations

7 xi Appendix 11C. Plant Example of Unplanned Incidents Causal Factors Analysis Appendix 11D. Example of Plant Accident/Incident Reporting Procedures Company Standards, Codes, and Regulations Overview External Codes, Regulations Internal Standards Appendix 12A. Example of Occupational Safety Standards Guidelines Appendix 12B. Example of Critical Operating Parameters: Interpretation Guidelines Appendix 12C. Example of Manufacturing Standards Appendix 12D. Example of Hazardous Systems (Existing System) Audits and Corrective Actions Overview Process Safety Management Systems Audits Process Safety Audits Compliance Reviews Internal/External Auditors Corrective Actions Appendix 13A. Protocol for Estimating Progress of Implementation of CCPS Guidelines for Technical Management of Chemical Process Safety Appendix 13B. "Key Questions" for the Elements of Process Hazards Management Appendix 13C. Example of Process Safety Audit Appendix 13D. Example of Safety and Property Protection Procedures

8 xii 14. Enhancement of Process Safety Knowledge Overview Quality Control Programs and Process Safety Professional and Trade Association Programs CCPS Programs Research, Development, Documentation and Implementation Improved Predictive Systems Appendix 14A. Professional Industry Organizations Offering Process Safety Enhancement Appendix 14B. Center for Chemical Process Safety Publications, Conferences, and Other Educational Materials Appendix 14C. Examples of Subjects Covered in Process Safety Libraries Bibliography Index