Preface... Acknowledgments... Glossary... xi xiii xv 1. Introduction... 1 1.1 Process Safety Management Activities of the Center for Chemical Process Safety (CCPS)... 1 1.2 Definition of "Process Safety Management"... 2 1.3 Scope... 4 2. Management Systems and the Management of Chemical Process Safety... 7 2.1 Introduction... 7 2.2 Management Systems for Chemical Process Safety... 7 2.3 Major Considerations for Developing and Implementing a Process Safety Management System... 8 Appendix 2A. Characteristics of a Management System... 9 3. Accountability: Objectives and Goals... 15 3.1 Overview... 15 3.2 Continuity of Operations... 16 3.3 Continuity of Systems... 17 3.4 Continuity of Organization... 17 3.5 Quality Process... 18 3.6 Control of Exceptions... 18 v
vi 3.7 Alternative Methods... 19 3.8 Management Accessibility... 20 3.9 Communications... 20 3.10 Company Expectations... 21 Appendix 3A. Example of the Management of Process Hazards... 23 4. Process Knowledge and Documentation... 31 4.1 Overview... 31 4.2 Chemical and Occupational Hazards... 32 4.3 Process Definition/Design Criteria... 35 4.4 Process and Equipment Design... 35 4.5 Protective Systems... 36 4.6 Normal and Upset Conditions... 36 4.7 Process Risk Management Decisions... 37 4.8 Company Memory (Management of Information)... 37 Appendix 4A. Example of a Typical Material Safety Data Sheet... 38 Appendix 4B. Lead Questions (Hazardous Conditions)... 40 Appendix 4C. Example of Process Definition/Design Criteria... 42 Appendix 4D. Examples of Typical Protective Systems/Equipment Data... 43 Appendix 4E. Example of Components Included in Process Knowledge and Documentation... 54 5. Process Safety Review Procedures for Capital Projects... 47 5.1 Overview... 47 5.2 Appropriation Request Procedures... 48 5.3 Hazard Reviews... 48 5.4 Sitting... 49
vii 5.5 Plot Plan... 49 5.6 Process Design and Review Procedures... 50 5.7 Project Management Procedures and Controls... 50 Appendix 5A. Plant Example of Organization of Process Hazard Review for Appropriation Requests... 51 Appendix 5B. Plant Example of Plant Procedures: "Description of Hazard Review for Appropriation Requests"... 53 Appendix 5C. Example of Plant Procedures for Appropriation Request Information and Approvals... 56 Appendix 5D. Plant Example of "Standard Practice for Process Reviews"... 59 6. Process Risk Management... 65 6.1 Overview... 65 6.2 Hazard Identification... 66 6.3 Risk Analysis of Operations... 67 6.4 Reduction of Risk... 67 6.5 Residual Risk Management... 68 6.6 Process Management during Emergencies... 68 6.7 Encouraging Client and Supplier Companies to Adopt Similar Risk Management Practices... 68 6.8 Selection of Businesses with Acceptable Risks... 69 Appendix 6A. Plant Example of Hazard Identification... 70 Appendix 6B. Plant "X" Risk Analysis of Operations... 73 Appendix 6C. Plant "Y" Risk Analysis of Operations... 74 Appendix 6D. Example of Process Management Used during Emergencies... 94
viii 7. Management of Change... 105 7.1 Overview... 105 7.2 Change of Process Technology... 106 7.3 Change of Facility... 107 7.4 Organizational Changes... 107 7.5 Variance Procedures... 107 7.6 Permanent Changes... 108 7.7 Temporary Changes... 108 7.8 Description of Examples... 108 Appendix 7A. Management of Change Policy... 110 Appendix 7B. Guideline for Review of Plant Changes or Modifications... 122 Appendix 7C. Control of Change Safety Management Practices... 124 Appendix 7D. Control of Changes... 126 Appendix 7E. Example of Change of Process Technology... 136 Appendix 7F. Example of Safety Assessment Form for Plant Modification Work... 139 Appendix 7G. Example of Management of Organization or Staffing Change... 141 Appendix 7H. Example of Variance Procedure and Variance Request Form... 142 Appendix 7I. Permanent Change Considerations... 145 Appendix 7J. Example of Jumpers/Bypasses Logging... 146 8. Process Equipment Integrity... 149 8.1 Overview... 149 8.2 Reliability Engineering... 150 8.3 Materials of Construction... 150 8.4 Fabrication and Inspection Procedures... 152 8.5 Installation Procedures... 152
ix 8.6 Preventative Maintenance... 152 8.7 Process, Hardware and Systems Inspection and Testing... 153 8.8 Maintenance Procedures... 153 8.9 Alarm and Instrument Management... 153 8.10 Decommissioning and Demolition Procedures... 154 Appendix 8A. Example of Plant Management System for Materials of Construction (MOC)... 155 Appendix 8B. Example of Test and Inspection Equipment and Procedures... 157 Appendix 8C. Example of Field Inspection and Testing of Process Safety Systems... 162 Appendix 8D. Example of a Hot Work Permit... 166 Appendix 8E. Example of Criteria for Test and Inspection of Safety Relief Devices... 169 Appendix 8F Example of Management System for Critical and Unique Safety Features... 187 Appendix 8G. Table of from Chemical Manufacturers Association Fixed Equipment Inspection Guide... 198 9. Human Factors... 199 9.1 Overview... 199 9.2 Operator/Process and Operator/Equipment Interfaces... 199 9.3 Administrative Controls Versus Hardware... 200 9.4 Human Error Assessment... 201 Appendix 9A. Human Factors Considerations in Some of the Key Elements of Process Safety Management... 203 10. Training and Performance... 215 10.1 Overview... 215 10.2 Definition of Skills and Knowledge... 216
x 10.3 Design of Operating and Maintenance Procedures... 216 10.4 Initial Qualifications Assessment... 217 10.5 Selection and Development of Training Program... 217 10.6 Measuring Performance and Effectiveness... 217 10.7 Instructor Program... 218 10.8 Records Management... 218 10.9 Ongoing Performance and Refresher Training... 218 Appendix 10A. Example of Operator Process Safety Training Program... 219 Appendix 10B. Example of Maintenance Training Program for Process Safety... 225 Appendix 10C. Example of Operations Technical Staff Training Program... 232 Appendix 10D. Example of Maintenance Training Implementation (Estimated Cost/Person)... 244 Appendix 10E. Example of Instructional Standards... 245 Appendix 10F. Example of Refresher Training Course Frequencies... 246 11. Incident Investigation... 247 11.1 Overview... 247 11.2 Major Incidents... 248 11.3 Third-Party Participation... 249 11.4 Follow-Up and Resolution... 250 11.5 Communication... 250 11.6 Incident Recording, Reporting, and Analysis... 250 11.7 Near Miss Reporting... 251 Appendix 11A. Example of Extraordinary Event Notification, Investigating, and Reporting... 253 Appendix 11B. Example of Plant Follow-Up Procedures for Accident/Incident Investigation Recommendations... 258
xi Appendix 11C. Plant Example of Unplanned Incidents Causal Factors Analysis... 259 Appendix 11D. Example of Plant Accident/Incident Reporting Procedures... 261 12. Company Standards, Codes, and Regulations... 265 12.1 Overview... 265 12.2 External Codes, Regulations... 266 12.3 Internal Standards... 266 Appendix 12A. Example of Occupational Safety Standards Guidelines... 269 Appendix 12B. Example of Critical Operating Parameters: Interpretation Guidelines... 291 Appendix 12C. Example of Manufacturing Standards... 296 Appendix 12D. Example of Hazardous Systems (Existing System)... 302 13. Audits and Corrective Actions... 313 13.1 Overview... 313 13.2 Process Safety Management Systems Audits... 316 13.3 Process Safety Audits... 317 13.4 Compliance Reviews... 318 13.5 Internal/External Auditors... 318 13.6 Corrective Actions... 318 Appendix 13A. Protocol for Estimating Progress of Implementation of CCPS Guidelines for Technical Management of Chemical Process Safety... 319 Appendix 13B. "Key Questions" for the Elements of Process Hazards Management... 331 Appendix 13C. Example of Process Safety Audit... 339 Appendix 13D. Example of Safety and Property Protection Procedures... 347
xii 14. Enhancement of Process Safety Knowledge... 373 14.1 Overview... 373 14.2 Quality Control Programs and Process Safety... 373 14.3 Professional and Trade Association Programs... 374 14.4 CCPS Programs... 374 14.5 Research, Development, Documentation and Implementation... 375 14.6 Improved Predictive Systems... 375 Appendix 14A. Professional Industry Organizations Offering Process Safety Enhancement... 377 Appendix 14B. Center for Chemical Process Safety Publications, Conferences, and Other Educational Materials... 380 Appendix 14C. Examples of Subjects Covered in Process Safety Libraries... 383 Bibliography... 385 Index... 389