ADVANCING PROCESS SAFETY WEBINAR SERIES. 2018: Webinar 1 out of 5 Tuesday, February 27th

Transcription

1 ADVANCING PROCESS SAFETY WEBINAR SERIES 2018: Webinar 1 out of 5 Tuesday, February 27th

2 Agenda 1. Introduction and Purpose Steve Mason, LyondellBasell Ind. 2. Process Safety Event Collection Sheet Felicia Miller, Delek and Dan Wilczynski, Marathon Petroleum Company A. New features B. Example review C. How to submit to AFPM and API 2. Upcoming Advancing Process Safety Opportunities Steve Mason, LyondellBasell Ind. A. Conferences B. Publications C. Webinars 2

3 Purpose Update participants on recent learnings stemming from AFPM/API Advancing Process Safety programs Industry Learnings and Outreach including Event Sharing and API RP 754 Hazard Identification and Practice Sharing Site Assessments Regional Networks Human Reliability: Permit to Work and Fired Heaters Mechanical Integrity To ensure consistency in Tier 1 and 2 metrics reporting in order to establish credibility and validity To share learnings regarding the effective implementation of Tier 1-2 lagging/leading metrics 3

4 Trend Charts for PSE 1 and 2 4

5 2016 Participation Petroleum Refining 34 companies representing 101 facilities 95% of Refining capacity Petrochemical Manufacturing 22 companies representing 118 facilities Total for RF and PC 56 Companies representing sites 219 5

6 Process Safety Event Collection Spreadsheet What s New and Example Review 6

7 Point of Release Detail 1 and Detail 2 Addition Point of Release Atmospheric tank Blow er/fan Compressor Cooling Tow er Filter/Coalescer/Strainer Fired Boiler Flare/Relief System Furnace/fired heater Heat exchanger Instrumentation Piping system, large bore(>2) Piping system, small bore( 2) Pressure Vessel Pump Reactor Other (describe) PoR Detail 1 Air Cooler Type Analyzer Auxiliary System Leak Boil over Casing Leak Channel Head / Tubesheet / Gasket Leak Control valve Dead leg Directly to atm Drum Expansion joint Firebox explosion Fitting leak Flange / Gasket Leak Flare liquid carryover / rainout Flare pilots out Flare system leak Flowmeter Fuel leak Head / closure gasket leak Hose leak Housing leak Insufficient information Lack of vapor controls Leak Level instrument Open ended line Other PoR Detail 1 (cont'd) Overfill Packing leak Piping leak Piping repair clamp leak Pressure boundary leak Pressure instrument Pressurized storage Process tube leak PVC or other non-metallic Relief valve leak Roof sinking Seal leak Shell and tube leak Shell leak Sight glass Sight flow indicator Small chemical injection pump Steam / water tube leak Temperature instrument Threaded fitting leak Tower Toxic release Tube leak Tubing leak Valve Vapor / gas blow thru PoR Detail 2 2" or less Body failure Braided metal Chemical hose Copper tubing Crack / hole During blind installation / removal Engineered clamp Fitting body leak Fitting / connection Flange face damage Gasket Gasket failed Glass failure Greater than 2" diameter Insufficient information Leak at fitting / Leak in hose Loose bolts Loose fitting Plastic tubing SS tubing Threaded fitting leak Utility hose Valve body leak Valve leak thru Valve left open Valve packing leak Wrong gasket

8 Modifications Associated with Causal Factors 3 Max Details for Each Causal Factor

9 QC Check

10 Importing API RP 754 Data to Event Sharing AFPM has implemented a process where companies can request that their API RP 754 submittals be imported into their Event Sharing queue. Process Company identifies which events they want imported to event sharing when they submit their API RP 754 data AFPM performs QAQC in April Once final report is published, AFPM will import events for companies into the company Administrator s queue

11 PSE Example Entry Review Questions and Clarifications Let s Walk Through an Example 11

12 12 PSE 754 Submissions -AFPM Submissions can be ed to either - Toby Palmer (tpalmer@vaultconsulting.com) - Anna Scherer (ascherer@afpm.org) -API Submissions can be ed to - Alexa Carlson(CarlsonA@api.org) Both associations have a hard deadline of March 9, For questions on API 754 PSE interpretations please - Heidi Keller (KellerH@api.org)

13 Look out for APS Presentations at the following Meetings! AFPM Annual Meeting New Orleans, LA March API / AFPM Spring Operating Practices Symposium Seattle, WA - April 18 Registration Open: CCPS Global Congress on Process Safety Orlando, FL April AFPM Reliability and Maintenance Conference San Antonio, TX May 19-22

14 Registration: g/microsite/nsc18 AFPM National Occupational & Process Safety Conference Registration Open May 15-16, San Antonio, TX All Regions Meeting Process and Occupational Regional Networks May 17 Awards Event Evening of May 16

15 Walk the Line Workshop July 25-26, 2018 Houston Area, TX July 25: 1:00-5:00pm Cocktail reception July 26: 8:00am-1:30pm Registration to Open in April Agenda General Session Presentation and Panel Getting Started Breakout Session Operational Readiness and Commissioning Measuring Success WTL Technology Sustainability and Ownership

16 Process Safety Related Documents Coming Soon AFPM Practices Sharing: Temporary Leak Repair Checklist and Form This practice provides a checklist that serves as a template for the review of potential hazards of temporary repairs that can include installation of clamps, enclosures, overlays, wraps and Tell-Tale (T-T) pins, including the re-tightening and reinjection of sealant in temporary repair enclosures to help prevent loss of containment events. Control of Defeat of Safety Critical Equipment The purpose of the Control of Defeat work practice is to ensure that the necessary analysis, authorization, communications and recordkeeping is performed when disabling or impairment of SHE (Safety, Health, Environment) Critical Devices occurs. Radio Communications Protocol This practice utilizes defined radio communication protocol in an operation that requires close coordination between field and console operators is important to effective performance and avoidance of unintended consequences.

17 Webinars What do the Webinars cover? Focused Topics New Documents Coming from AFPM API 754 Queries of Interests Planned 2018 Webinars Date Topics February 27 April 10 Note: Change from April 17 to April 10 June 19 PSE Data Collection Integrity Operating Windows Common Pitfalls and Company Practices Speakers: John Reynolds, Intertek Chad Patschke, Ethos MI Clay White, P66 (Invited) Mike Urzendowski, Valero (Invited) HR - Fired Heater; PSE Data Collection Results September 12 Human Reliability (HR) Permit to Work November 13 Best of Regional Networks

18 How to Access the Safety Portal? All AFPM Members have access to the AFPM Safety Portal To see if you are a member: Safety Portal Link: You will need your AFPM Username and Password to access the Portal. If you have forgotten it or need to set one up, follow the instructions on the login page. Note: For Access to Process Safety Metrics, Injury & Illness Metrics, and Event Sharing database, you will need to get permission from your company s database administrator. Those individuals are listed in the bottom right hand corner of the Portal Homepage. For all questions and information, contact: Lara Swett Senior Director, Safety Programs AFPM lswett@afpm.org