Guidelines for Process Safety During the Transient Operating Mode E-Book

• Herausgeber: John Wiley & Sons
• Kategorie: Fachliteratur
• Sprache: Englisch

Seitenzahl: 262

Veröffentlichungsjahr: 2020

Beschreibung

Prevent operational incidents and reduce risks with an essential CCPS guide You can help your company reduce its operating risks by learning how to effectively manage transient operations and avoid major incidents. Startups and shutdowns, known as transient operations, can be high-risk periods for manufacturing facilities. Guidelines for Process Safety During Transient Operations offers useful guidance in preparing for the safe startup and shutdown of chemical processes.With an understanding of the risks involved, you can work proactively to prevent fatalities, serious injuries, reduced productivity, and costly damage. This essential guide for plants provides clear examples of how to anticipate and avoid major issues. The book examines safe shutdown procedures in the event of an emergency. You will also gain direction on how to resume operations safely after an unexpected shutdown. The book supports anyone tasked with regulating and overseeing chemical plants and procedures, whether you are an engineer, manager, or government professional. * Minimize operating risks through the effective management of transient operations * Establish safe start-up and shutdown procedures for chemical processes * Be ready to safely shut down processes in the event of an emergency * Learn from real world examples of start-up or shutdown incidents * Review procedures and engineering controls that help prevent or reduce the effects of incidents involving transient operations Guidelines for Process Safety comes to you from The Center for Chemical Process Safety (CCPS), which offers advanced thinking in the critical area of process safety. The organization develops technology and management practices for companies seeking to reduce hazards within the chemical and petrochemical industries.

Leseprobe

Table of Contents

Cover

Guidelines for Process Safety During the Transient Operating Mode:

Copyright

List of Figures

List of Tables

Acronyms and Abbreviations

Glossary

Acknowledgments

Dedication

Foreword

Preface

1 Introduction

1.1 Introduction

1.2 Scope

1.3 Audience

1.4 Benefits

1.5 Applying CCPS Risk Based Process Safety (RBPS)

1.6 Incident discussions and guidance

1.7 Framework

2 Defining the Transition Times

2.1 Introduction

2.2 Defining the modes of operation

2.3 Responses to deviations during operations

2.4 A start‐up incident

Part I: Normal Operations

3 Normal Operations

3.1 Introduction

3.2 The normal operation

3.3 Procedures

3.4 Performing a normal shut‐down

3.5 Start‐up after a normal shut‐down

3.6 Incidents and lessons learned

3.7 How the RBPS elements apply

4 Process Shutdowns

4.1 Introduction

4.2 The process shutdown

4.3 Projects requiring equipment or process unit shutdowns

4.4 A brief project life cycle phase overview

4.5 Preparing for planned project‐related shutdowns

4.6 Start‐up after planned project‐related shutdowns

4.7 Incidents and lessons learned

4.8 How the RBPS elements apply

5 Facility Shutdowns

5.1 Introduction

5.2 The facility shutdown

5.3 Projects requiring a process unit or facility project‐related shutdown

5.4 Preparing for a facility project‐related shutdown

5.5 Start‐up after a facility project‐related shutdown

5.6 Incidents and lessons learned

5.7 How the RBPS elements apply

Part II: Abnormal and Emergency Operations

6 Recovery

6.1 Introduction

6.2 Recovering from an abnormal operation

6.3 Anticipating abnormal operations

6.4 Managing abnormal operations

6.5 Incidents and lessons learned

6.6 How the RBPS elements apply

7 Unscheduled Shutdowns

7.1 Introduction

7.2 Unscheduled shutdowns

7.3 Anticipating and preparing for unscheduled shutdowns

7.4 Start‐up after activating an unscheduled shut‐down

7.5 Managing unscheduled shutdowns caused by natural hazard events

7.6 Incidents and lessons learned

7.7 How the RBPS elements apply

8 Emergency Shutdowns

8.1 Introduction

8.2 Emergency shutdowns

8.3 Safely responding to an incident

8.4 Anticipating and preparing for shut‐downs in an emergency

8.5 Start‐up after an emergency shutdown

8.6 Incidents and lessons learned

8.7 How the RBPS elements apply

Part III: Other Considerations

9 Other Transition Time Considerations

9.1 Introduction

9.2 A Life Cycle overview

9.3 Commissioning and initial start‐up considerations

9.4 Incidents and lessons learned, commissioning and initial start‐ups

9.5 End‐of‐life shut‐down considerations

9.6 Mothballing considerations

9.7 Incidents and lessons learned, mothballing

9.8 Decommissioning considerations

9.9 Incidents and lessons learned, decommissioning

9.10 How the RBPS elements apply

10 Risk Based Process Safety (RBPS) Considerations

10.1 Introduction

10.2 An RBPS Overview

10.3 Applying RBPS to each transient operating mode

10.4 Effects of weak operational discipline

10.5 Approach for improving process safety performance

AppendixTransient operating modes: incident review and guidance

A.1. Introduction

A.2. Review of incidents during transient operating modes

A.3. Managing the unexpected during transient operating modes

References

Index

End User License Agreement

List of Tables

Chapter 1

Table 1.1

List of the different types of transient operating modes.

Table 1.2

Chapter framework for this guideline.

Chapter 2

Table 2.1

Definitions for the modes of operation.

Table 2.2

Definitions for the transient operating modes.

Chapter 4

Table 4.1

Handover topics between the construction and the commissioning/start‐up

...

Table 4.2

Handover topics between the commissioning/start‐up and the operations s

...

Chapter 5

Table 5.1

Scope of work for the Dolphin Energy Limited shutdowns.

Table 5.2

Safety summary for the Dolphin Energy Limited shutdowns.

Table 5.3 Points to remember when starting up after a facility shutdown time

Chapter 6

Table 6.1 Example guidewords used in a HAZOP study for a continuous process.

Chapter 7

Table 7.1 Framework for anticipating and responding to natural disasters. (Ad...

Chapter 9

Table 9.1

Definitions of the Process or Equipment Life Cycle Stages.

Table 9.2

Handover topics between the end‐of‐life project initiation stage to the

...

Chapter 10

Table 10.1 Examples of good operational discipline for process design, hazard...

Table 10.2

Examples of good operational discipline for operations and maintenance

...

Table 10.3

Examples of good operational discipline for changes, emergency respons

...

Table 10.4

Examples of good operational discipline for monitoring effectiveness.

...

1

Table A.2-1 Phases for the transient operating modes.

Table A.2-2 Summary of the incidents during the transient operating mode.

Table A.3-1 Loss of utilities checklist.

Table A.3-2 Hazard and Operability (HAZOP) Study guideword matrix.

Table A.3-3 List of Process Hazard Analysis (PHA) team HAZOP assumptions

Table A.3-4 Steps for effectively managing unexpected situations during start...

List of Illustrations

Chapter 1

Figure 1.1

Three types of facility operations and their corresponding transi

...

Figure 1.2

Example normal operations flow chart.

Figure 1.3

Example abnormal and emergency operations flow chart.

Chapter 2

Figure 2.1

The anhydrous ammonia release incident at start‐up.[

18

]

Figure 2.2

Timeline used to determine which transient operating mode applies

Chapter 3

Figure 3.1

Transient operating modes during normal operations. (Adapted from

Figure 3.2

Example timeline for a normal operation—continuous process.

Figure 3.3 Example timeline for a normal operation—batch process.

Figure 3.4 Types of engineering and administrative control responses to proc...

Figure 3.5 Example of pressure vessel control limits.

Chapter 4

Figure 4.1

Transient operating modes associated with process and facility sh

...

Figure 4.2

Stages in the capital project's life cycle. (Adapted from [

31

Figure 4.3

Example timeline for a process or facility shutdown.

Chapter 6

Figure 6.1 Types of responses to process aim deviations.

Figure 6.2 Transient operating modes associated with abnormal and emergency ...

Figure 6.3 Example timeline for an abnormal operation on a continuous proces...

Figure 6.4 Example abnormal situation fault detection model.

Figure 6.5 Incident timeline for the perceived recovery, subsequent runaway ...

Chapter 7

Figure 7.1 Example timeline for an abnormal operation with a normal shut‐dow...

Figure 7.2 The area impacted by the anhydrous ammonia release incident at st...

Chapter 8

Figure 8.1 Abnormal and emergency operations flow chart with different types...

Figure 8.2

Example timeline for an abnormal operation resulting in an emerge

...

Figure 8.3

Example timeline for an abnormal operation resulting in an emerge

...

Chapter 9

Figure 9.1

Initial start‐up and final shut‐down stages in the project life c

...

Figure 9.2

Example project life cycle stages in context of the equipment or

...

Chapter 10

Figure 10.1

CCPS Risk Based Process Safety (RBPS) Model.

Figure 10.2

Summary of CCPS RBPS Weaknesses from Incidents Occurring During

...

1

Figure A.2-1 Timeline of when incidents occurred during the transient operat...

Guide

Cover Page

Title Page

Copyright

Dedication

Table of Contents

Begin Reading

Appendix Transient operating modes: incident review and guidance

Index

WILEY END USER LICENSE AGREEMENT

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Guidelines for Process Safety During the Transient Operating Mode:

Managing Risks during Process Start‐ups and Shut‐downs

Center for Chemical Process Safetyof theAmerican Institute of Chemical Engineers

New York, NY

This edition first published 2021

© 2021 the American Institute of Chemical Engineers

A Joint Publication of the American Institute of Chemical Engineers and John Wiley & Sons, Inc.

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, except as permitted by law. Advice on how to obtain permission to reuse material from this title is available at http://www .wiley.com/g o/permissions.

The rights of CCPS to be identified as the author of the editorial material in this work have been asserted in accordance with law.

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ISBN: 9781119529156

Cover Design: Wiley‐AlChE

Cover images: Silhouette, oil refinery © manyx31/istock.com,

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This book is one in a series of process safety guidelines and concept books published by the Center for Chemical Process Safety (CCPS). Refer to www.wiley.com/go/ccps for full list of titles in this series.

It is sincerely hoped that the information presented in this document will lead to an even more impressive safety record for the entire industry; however, neither the American Institute of Chemical Engineers, its consultants, CCPS Technical Steering Committee and Subcommittee members, their employers, their employers' officers and directors, nor ioMosaic Corporation, and its employees and subcontractors warrant or represent, expressly or by implication, the correctness or accuracy of the content of the information presented in this document. As between (1) American Institute of Chemical Engineers, its consultants, CCPS Technical Steering Committee and Subcommittee members, their employers, their employers' officers and directors, and ioMosaic Corporation and its employees and subcontractors, and (2) the user of this document, the user accepts any legal liability or responsibility whatsoever for the consequence of its use or misuse

List of Figures

Figure 1.1 Three types of facility operations and their corresponding transient operating modes. 9

Figure 1.2 Example normal operations flow chart. 12

Figure 1.3 Example abnormal and emergency operations flow chart. 14

Figure 2.1 The anhydrous ammonia release incident at start‐up. 24

Figure 2.2 Timeline used to determine which transient operating mode applies 25

Figure 3.1 Transient operating modes during normal operations. 31

Figure 3.2 Example timeline for a normal operation—continuous process. 32

Figure 3.3 Example timeline for a normal operation—batch process. 33

Figure 3.4 Types of engineering and administrative control responses to process deviations. 35

Figure 3.5 Example of pressure vessel control limits. 37

Figure 4.1 Transient operating modes associated with process and facility shutdowns. 48

Figure 4.2 Stages in the capital project’s life cycle. 55

Figure 4.3 Example timeline for a process or facility shutdown. 64

Figure 6.1 Types of responses to process aim deviations. 102

Figure 6.2 Transient operating modes associated with abnormal and emergency operations. 104

Figure 6.3 Example timeline for an abnormal operation on a continuous process with recovery. 106

Figure 6.4 Example abnormal situation fault detection model. 110

Figure 6.5 Incident timeline for the perceived recovery, subsequent runaway reaction and explosion fault detection model. 113

Figure 7.1 Example timeline for an abnormal operation with a normal shut‐down (an unscheduled shutdown). 118

Figure 7.2 The area impacted by the anhydrous ammonia release incident at start‐up. 130

Figure 8.1 Abnormal and emergency operations flow chart with different types of emergency shut‐downs 146

Figure 8.2 Example timeline for an abnormal operation resulting in an emergency shut‐down to the normal at‐rest, idle state. 148

Figure 8.3 Example timeline for an abnormal operation resulting in an emergency shut‐down to a different, safe state. 150

Figure 9.1 Initial start‐up and final shut‐down stages in the project life cycle. 161

Figure 9.2 Example project life cycle stages in context of the equipment or process life cycle stages. 162

Figure 10.1

CCPS Risk Based Process Safety (RBPS) Model. 188

Figure 10.2

Summary of CCPS RBPS Weaknesses from Incidents Occurring During the Transient Operating Modes 195

Figure A.2 1 Timeline of when incidents occurred during the transient operating mode. 211

List of Tables

Table 1.1 List of the different types of transient operating modes. 10

Table 1.2 Chapter framework for this guideline. 11

Table 2.1 Definitions for the modes of operation. 18

Table 2.2 Definitions for the transient operating modes. 20

Table 4.1 Handover topics between the construction and the commissioning/start‐up stages. 68

Table 4.2 Handover topics between the commissioning/start‐up and the operations stages. 69

Table 5.1 Scope of work for the Dolphin Energy Limited shutdowns. 85

Table 5.2 Safety summary for the Dolphin Energy Limited shutdowns. 86

Table 5.3 Points to remember when starting up after a facility shutdown time 93

Table 6.1 Example guidewords used in a HAZOP study for a continuous process. 101

Table 7.1 Framework for anticipating and responding to natural disasters. 123

Table 9.1

Definitions of the Process or Equipment Life Cycle Stages. 163

Table 9.2

Handover topics between the end‐of‐life project initiation stage to the end‐of‐life stage. 168

Table 10.1

Examples of good operational discipline for process design, hazards identification, and risk evaluations. 206

Table 10.2

Examples of good operational discipline for operations and maintenance. 207

Table 10.3

Examples of good operational discipline for changes, emergency response, and incident investigations. 208

Table 10.4

Examples of good operational discipline for monitoring effectiveness. 208

Table A.3 1 Loss of utilities checklist. 224

Table A.3 2 Hazard and Operability (HAZOP) Study guideword matrix. 226

Table A.3 3 List of Process Hazard Analysis (PHA) team HAZOP assumptions 230

Table A.3‐4 Steps for effectively managing unexpected situations during start‐up 236

Acronyms and Abbreviations

AIChE

American Institute of Chemical Engineers

C

Consequence (

see Equation 10.1

)

CCPS

Center for Chemical Process Safety

ERP

Emergency Response Plan

ERT

Emergency Response Team

ESD

Emergency Shutdown Device

ESS

Emergency Shutdown System

F

Frequency (

see Equation 10.1

)

HAZOP

Hazards and Operability Study

HIRA

Hazards Identification and Risk Analysis

ITPM

Inspection, Testing, and Preventive Maintenance program

LOPA

Layer of Protection Analysis

LL

Lesson Learned

LS

Lesson Strength

LTI

Lost Time Injury

MOC

Management of Change

MTC

Medical Treatment Case

OD

Operational Discipline (

see Equation 10.1

)

ORR

Operational Readiness Review

PDCA

Plan, Do, Check, Act

PHA

Process Hazards Analysis

PPE

Personal Protective Equipment

PSSR

Pre‐Startup Safety Review

R

Risk (

see Equation 10.1

)

RBPS

CCPS Risk Based Process Safety

SIMOPS

Simultaneous Operations

SIS

Safety Instrumented System

SWP

Safe Work Practice

US CSB

United States Chemical Safety and Hazard Investigation Board

Acknowledgments

The American Institute of Chemical Engineers (AIChE) and the Center for Chemical Process Safety (CCPS) express their appreciation and gratitude to all members of the Guidelines for Process Safety During the Transient Operating Mode Subcommittee for their generous efforts in the development and preparation of this important guideline. CCPS also wishes to thank the subcommittee members' respective companies for supporting their involvement during the different phases in this project.

Subcommittee Members (2016‐2018):

Theresa Broussard, Chair

Chevron Corporation

Susan Bayley

Linde Process Plants, Inc.

Don Connolley

BP Corporation NA, Inc.

Eddie Dalton

BASF Corporation

Reyyan Koc Karabocek

ExxonMobil

Pamela Nelson

Solvay

Jitesh Patel

New Jersey DEP

Scott Schiller

BakerRisk

Dan Sliva

CCPS Staff Consultant

Sandeep Vipra

Reliance

Elliot Wolf

Chemours

The collective industrial experience and know‐how of the subcommittee members makes this guideline especially valuable to those who develop and manage process safety programs and management systems.

Before publication, all CCPS guidelines are subjected to a peer review process. CCPS gratefully acknowledges the thoughtful comments and suggestions of the peer reviewers. Their work enhanced the accuracy and clarity of this guideline.

Initial manuscript peer reviewers (2018):

Daniel Callahan

Stepan

Charles Foshee

Chevron

Jennifer Mize

Eastman

Al Morrison

Chevron

Although the peer reviewers provided comments and suggestions, they were not asked to endorse this guideline and did not review the final manuscript before its release.

The book committee wishes to express their appreciation to Elena Prats and Kathy Anderson, ioMosaic Corporation, for their contributions in preparing the guideline's draft manuscript. Sincere appreciation is extended to Dr. Bruce K. Vaughen, PE, CCPSC, of CCPS for his contribution in restructuring the book committee's efforts, addressing the final comments from both the book's committee and peer reviewers, and in creating the final, published manuscript.

Before publication of the final manuscript for this guideline, an additional technical review of each of the chapter's drafts and the restructured and enhanced manuscript provided additional insights that were incorporated into the final, published manuscript. Much appreciation is extended to the final reviewers for their time.

Restructured draft and final manuscript reviewers (2020):

Theresa Broussard, Chair

Chevron Corporation

Dan Sliva

CCPS Staff Consultant

Jennifer Bitz

CCPS, Project Manager

Pete Lodal

Eastman

Dr. Anil Gokhale, PE

CCPS Project Director

Special appreciation is extended to Kiezha Ferrell for copy editing the draft of the final manuscript.

Dedication

This guideline is dedicated to those who have been injured or lost their lives, and their families, as a result of incidents that occurred during transition times in the industries handling hazardous materials and energies. Hazards and risk management approaches continue to improve facilities based on the learnings from these incidents. Since there is a better understanding of some of the human performance‐related issues today, improved engineering and administrative controls have been established to help prevent these type of incidents from occurring again. This guideline puts forth a framework that applies the Risk Based Process Safety (RBPS) principals to activities specifically associated with the transient operating mode. It is the hope of the authors that the risk reduction approaches provided in this guideline can be integrated and implemented within the existing process safety and risk management systems in organizations striving toward world‐class process safety performance.

“Do not let the world's adversity stifle your enthusiasm, nor blind your vision. The struggle towards excellence should ever be conducted on the high plains of self‐confidence, a sense of purpose, and positive thought. Go forth with a desire to accomplish…with a desire to contribute to our society.”

Ronald E. McNair, 1950 ‐ 1986NASA Astronaut ‐ Space Shuttle Challenger

Foreword

As the Chairperson of the U.S. Chemical Safety and Hazard Investigation Board (CSB), which independently investigates the root causes of incidents involving hazardous substance releases, I have seen the complex processes involved in transient operations. More importantly, I, and many dedicated safety professionals, have borne witness to the human cost, property damage, and environmental destruction arising from infrequent, non‐routine procedures used at company facilities.

The CSB previously has examined transient operations issues in its investigations, some of which are discussed in this book, including emergency shut‐down procedures, incidents resulting from start‐up activities, and incidents resulting from normal shut‐down activities. For example, lessons learned from start‐up operations have shown that facilities should follow established start‐up procedures, carefully perform pre‐start‐up safety reviews and thoroughly check equipment, piping, instrumentation and tanks for damage and safety system impairments. In the case of performing tasks that are not part of normal processing, and often those tasks that are completed under manual control or with less‐ frequent training, due diligence is necessary. Preparation and sound management systems are essential to ensure safe, predictable transient operations. Good safety practices are good business practices.

Beyond process or facility outages and decommissioning activities, companies face unplanned shut‐down and start‐up activities from extreme weather, malicious intent, and other external forces. The 2017 hurricane season in the United States was one of the most destructive in the country's history, requiring many companies to stop their operations temporarily, which would require them to start‐up again. Likewise, the world continues to be mindful of the risk of having unplanned or emergency outages due to malicious actors’ behaviors. These unexpected, complex challenges in managing chemical process hazards will remain a consistent consideration for the foreseeable future.

Yet, safety professionals also recognize that no single checklist is adequate to conduct a thorough risk assessment. Hazard identification is a critical first step to managing safety risks enough to prevent catastrophic, high impact incidents. CCPS and its dedicated expert volunteers and staff continuously strive to collect and share lessons in process safety. Their publications serve as one foundational element of process safety training and implementation programs. These guidelines are the next meaningful contribution to the chemical industry to enable facilities to follow established procedures and checklists related to transient operations.

American philosopher William James said, “To study the abnormal is the best way to understand the normal.” This book provides a valuable perspective into both the special characteristics of abnormal and unexpected facility operations. Facilities have the ability to adhere to appropriate safety management systems, engage in emergency planning and response activities in the event of an incident, and to learn from near misses or minor incidents to continually improve.