Guidelines for Writing Effective Operating and Maintenance Procedures E-Book

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

Seitenzahl: 168

Veröffentlichungsjahr: 2011

Beschreibung

The EPA investigation of a 1994 chemical plant tragedy concluded that "the explosion resulted from a lack of written safe operating procedures..." While good written procedures can't guarantee zero accidents, they can reduce the number of accidents caused by human error. This new book shows how to remedy this problem through selecting and implementing actions that promote safe, efficient operations and maintenance, improve quality, continuity, profitability and cost control, build upon and record process experience, and promote the concept that operating and maintenance procedures are vital plant components. It includes practical samples of procedure formats, checklists and many references.

Leseprobe

CONTENTS

Cover

Half Title page

Title page

Copyright page

Preface

Acknowledgements

Glossary

Chapter 1: Introduction to Effective Procedure Writing

1.1. Why Was This Book Written?

1.2. Book Objectives

1.3. The Current Worldwide Trend Toward Procedures

1.4. Who Should Use This Book?

1.5. Where Do You Go From Here?

Chapter 2: Process Safety, Environmental, and Quality Considerations

2.1. Purpose

2.2. Understanding the Guidelines and Regulations

2.3. Voluntary Guidelines

2.4. Governmental Regulations

2.5. Quality Considerations

2.6. Some Elements of Effective Procedures and Procedure Management Systems

2.7. Additional Considerations

2.8. Conclusion

Endnotes

Chapter 3: How to Design an Operating and Maintenance Procedure Management System

3.1. Purpose

3.2. The Importance of Written Procedures

3.3. Elements of a Comprehensive Procedure Management System

3.4. Determining Procedure Management System Requirements

3.5. Evaluating Your Current Practices

3.6. Identifying Your Resources

3.7. Designing and Implementing Your Procedure Management System

3.8. How to Determine Which Procedures to Write

3.9. Implementing a Procedure Project

3.10. Procedure Training

3.11. Maintaining and Improving Your Procedure Management System

3.12. Conclusion

Chapter 4: Writing Operating and Maintenance Procedures

4.1. Purpose

4.2. What Resources Do You Need Before You Begin Writing?

4.3. What Do We Know About the Procedure Users?

4.4. Considerations for Effective Procedures

4.5. Importance of Procedure Format

4.6. Introductory Sections

4.7. Procedure Steps Section

4.8. Drafting the Procedure

4.9. The Procedure Review and Approval Cycle

4.10. Special Considerations for Maintenance Procedures

4.11. Batch Process Considerations

Chapter 5: Elements of Effective Procedures

5.1. Purpose

5.2. Importance of Procedure Evaluation Criteria

5.3. Who Will Use the Procedure Evaluation Criteria?

5.4. Procedure Checklist Elements

Endnotes

Chapter 6: Writing Emergency Operating Procedures

6.1. Purpose

6.2. Defining Events Requiring Emergency Operating Procedures

6.3. Identifying Emergency Situations

6.4. Developing and Writing Emergency Operating Procedures

6.5. Directing the User to the Correct Emergency Operating Procedure

6.6. Incorporating Human Factors in Emergency Operating Procedures

6.7. Using Decision Aids

6.8. How Emergency Operating Procedures Link to the Emergency Response Plan

Endnotes

Chapter 7: Procedure Control

7.1. Purpose

7.2. What Is Procedure Control?

7.3. Controlling Procedure Revisions and Development

7.4. Who Should Review the Procedures?

7.5. Procedure Approval

7.6. Evaluating Procedures In Use

7.7. Electronic Document Control

Chapter 8: Procedure Development Costs and Benefits

8.1. Purpose

8.2. Reasons for Procedure Development

8.3. Procedure Development Costs

8.4. Return on Investment: Improvements You Can Expect from Effective Procedures

Endnotes

Appendix A: Selected Procedure Initiatives, Consensus Codes, and Regulations Affecting Procedures

Appendix B: Common Points of API, OSHA, and EPA

Appendix C: How to Determine the Tasks That Require Written Procedures

Assessing Training Needs

Appendix D: Procedure Performance Evaluation

Appendix E: Procedure Criteria Checklist

Endnote

Appendix F: Sample Procedure Formats

Appendix G: Sample Formats of Operating Limits Tables

General References

Index

GUIDELINES FOR Writing Effective Operating and Maintenance Procedures

Copyright © 1996American Institute of Chemical Engineers345 East 47th StreetNew York, New York 10017

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 without the prior permission of the copyright owner.

Library of Congress Cataloging-in Publication DataGuidelines for writing effective operating and maintenance procedures.p. cm.Includes bibliographical references (p. - ) and index.ISBN 0-8169-0658-01. Chemical engineering—Safety measures—Handbooks, manuals, etc. 2. Technical writing—Handbooks, manuals, etc. I. American Institute of Chemical Engineers. Center for Chemical Process Safety.TP149.G845    1996660′.2804′0684—dc20

96-33781CIP

This book Is available at a special discount when ordered In bulk quantities. For Information, contact the Center for Chemical Process Safety of the American Institute of Chemical Engineers at the address shown above.

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, the American Institute of Chemical Engineers, its consultants, CCPS Subcommittee members, their employers, their employers’ officers and directors, and NUS Training Corporation and its employees, officers and directors disclaim making or giving any warranties or representations, including with respect to fitness, intended purpose, use or merchantability and/or correctness or accuracy of the information presented in this document. As between (1) American Institute of Chemical Engineers, its consultants, CCPS Subcommittee members, their employers, their employers’ officers and directors, and NUS Training Corporation and its employees, officers and directors, and (2) the user of this document, the user accepts any legal liability or responsibility whatsoever for the consequences of its use or misuse.

PREFACE

For over 30 years the American Institute of Chemical Engineers (AIChE) has been involved with process safety and loss control issues in the chemical, petrochemical, hydrocarbon process and related industries and facilities. AIChE publications and symposia are information resources for the chemical engineering and other professions on the causes of process incidents and the means of preventing their occurrences and mitigating their consequences.

The Center for Chemical Process Safety (CCPS), a Directorate of the AIChE, was established in 1985 to develop and disseminate technical information for use in the prevention of major chemical process incidents. With the support and direction of the CCPS Advisory and Managing Boards, a multifaceted program was established to address the need for Process Safety Management systems to reduce potential exposures to the public, facilities, personnel, and the environment. This program involves the development and publication of Guidelines relating to specific areas of Process Safety Management; organizing, convening and conducting seminars, symposia, training programs, and meetings on process safety-related matters, and cooperation with other organizations, both internationally and domestically, to promote process safety. The CCPS’s activities are supported by funding and professional expertise by over 90 corporations. Several Government agencies also participate in CCPS’s endeavors.

In 1989, CCPS published the Guidelines for Technical Management of Chemical Process Safety, which presented a model for Process Safety Management characterized by twelve distinct, essential and interrelated elements. The Foreword to that volume stated:

For the first time, all the essential elements and components of a model of a technical management program in chemical process safety have been assembled in one document. We believe the Guidelines provide the umbrella under which all other CCPS Technical Guidelines will be promulgated.

One of the elements of chemical process safety developed in the Guidelines for Technical Management of Chemical Process Safety is training and performance. Operating and maintenance procedures are essential to achieving proper training and safe, efficient performance of operating and maintenance tasks. This book was written to assist all persons involved with operating and maintaining chemical process facilities in establishing a system to write and implement procedures. It is not intended to serve as a compliance manual to meet the specific requirements of any mandates, rules, laws or regulations. It emphasizes those principles needed to write, implement, and control effective operating and maintenance procedures. This Guideline, while dealing primarily with the preparation and control of procedures, also treats some of the other issues of the Training and Performance element of chemical process safety. The purpose of the examples within this guideline is solely to demonstrate a technique or methodology. The examples are not complete procedures and therefore are not intended to be evaluated for technical accuracy or soundness. Other Guidelines dealing specifically with training and the actual operation and maintenance of chemical facilities are also currently being prepared.

ACKNOWLEDGEMENTS

The American Institute of Chemical Engineers and the Center for Chemical Process Safety (CCPS) expresses its gratitude to all of the members of the Subcommittee on Writing Effective Operating and Maintenance Procedures for their unstinting efforts and technical contributions in the preparation of this Guideline. CCPS also expresses its appreciation to members of the Technical Steering Committee for their valuable advice and support.

The Chair of the Subcommittee on Writing Effective Operating and Maintenance Procedures was John A. McIntosh, III of Procter and Gamble. The Subcommittee members were Mr. Neil Maxson, Bayer Corporation (formerly Miles, Inc.); Lisa Loden and Tommy Northcutt, Lockheed Martin (formerly Martin-Marietta Energy Systems); Robert Kambach, BASF; William Fleming, Carmel Corona, Jr., and Vijay Surapaneni, Bristol-Myers Squibb Company; Ken Turnbull, Kathy Hartkey, Gus Wilson and Roman Wally of Texaco, Inc.; Peter Hughes of Novacor Chemicals Company, Ltd. and John R. Lockwood of BP America. Dr. Martin Gluckstein, P.E. was the CCPS staff liaison and was responsible for the overall administration and coordination of the project.

NUS Training Corporation, a Williams Knowledge Systems Company, Gaithersburg, MD, was the contractor responsible for preparing this Guideline. Mr. Michael Halpern was the NUS Training Project Leader. The principal NUS Training authors were Sandra Baker, Michael Halpern, and Kathryn Kidd. Mr. Robert Walter, formerly of NUS Training, was also a contributor. Portions of this book are materials reprinted or adapted from NUS Training Corporation’s Procedure Writing Workshop Manual (copyright 1990–1995).

CCPS also gratefully acknowledges the insight, thoughtful comments, and suggestions contributed by the following peer reviewers: Peter McGrath, Olin Corporation; Deric Crosby, PCR, Inc.; Peter Fletcher, Raytheon Engineers and Constructors, Inc.; J. Henry Blunt, Shell Oil Company; Thomas O. Gibson, The Dow Chemical Company; Rudolf Frey, The M. W. Kellogg Company; Glenn Damerell, 3M; Lester Wittenberg, AIChE/CCPS; Pamela Sutherland, Battelle; Tony R. Williams, JBF Associates, Inc.; John D. Snell, Occidental Chemical Corporation; and Leslie A. Scher, W. R. Grace & Co.

GLOSSARY

Accidental chemical release:

An unintended or sudden release of chemical(s) from manufacturing, processing, handling, or on-site storage facilities to the air, water, or land.

Administrative procedures:

Written instructions describing how to carryout programs such as procedure writing and training programs.

Branching:

A method used to send the reader to another location in the same procedure or to another procedure.

Checklist:

A written list in which each item is marked off (or acknowledged on a computer screen) as its status is verified.

Critical:

Relates to major environmental or safety risks.

Effective:

Producing a definitive or desired result.

Emergency operating procedures (EOP):

Written instructions that address actions to take to place a process in a safe and stable mode following a system upset.

Emergency Response Plan:

A written plan required by governmental agencies which addresses actions to take in case of plant fire, explosion, or accidental chemical release of predetermined severity.

EPA:

U.S. Environmental Protection Agency; Federal agency with environmental protection regulatory and enforcement authority.

Event:

An identifiable occurrence related to equipment performance or human action, or an occurrence external to the system that causes (or could cause) dangerous system upset. The cause or contributor to an incident or accident.

Facility:

Buildings, containers or equipment which contain a process.

Human factors:

A discipline concerned with designing machines, operations, and work environments so that they match human capabilities, limitations, and needs. Includes any technical work (engineering, procedure writing, worker training, worker selection, etc.) related to the human factor in worker-machine systems.

Incident:

An unplanned event or series of events and circumstances that may result in an undesirable consequence.

Job:

A group of closely related tasks that achieve a specific goal or involve a common product, process, or service.

Maintenance procedures:

Written instructions that address material control and maintenance practices needed to ensure system operability and integrity as well as maintenance, testing, and inspection frequency.

Management of Change:

A system to identify, review, and approve all modifications to equipment, procedures, raw materials and processing conditions, other than “replacement in kind,” prior to implementation.

Operating procedures:

Written step-by-step instructions and associated information (cautions, notes, warnings, etc.) for safely performing a task within operating limits.

Operating emergency:

An event (see definition) which can result in an accidental chemical release or injury if appropriate actions are not taken.

OSHA:

Occupational Safety and Health Administration of the U. S. Department of Labor; Federal agency with safety and health regulatory and enforcement authorities for most U.S. industry and business.

Probability:

The likelihood of occurrence of an event or an event sequence during an interval of time or the likelihood of the success or failure of an event on test or on demand.

Process:

Any activity involving a chemical including any use, storage, manufacturing, handling, or on-site movement of such chemicals, or combination of these activities.

Procedure management system:

System used to consistently control the development, maintenance, review, approval, and distribution of procedures to ensure that procedures are up-to-date, accessible, and accurate.

Process Hazards Analysis (PHA):

An organized effort to identify and evaluate hazards associated with chemical processes and operations to enable their control. This review normally involves the use of qualitative techniques to identify and assess the significance of hazards. Conclusions and appropriate recommendations are developed. Occasionally, quantitative methods are used to help prioritize risk reduction.

Process safety:

A discipline that focuses on the prevention of fires, explosions, and accidental chemical releases at chemical process facilities. Excludes classic worker health and safety issues involving work surfaces, ladders, protective equipment, etc.

Process Safety Management (PSM):

A program or activity involving the application of management principles and analytical techniques to ensure the safety of chemical process facilities. Sometimes called process hazard management.

Safety:

The expectation that a system does not, under defined conditions, lead to a state in which human life, economics or the environment is adversely affected.

System upset:

A condition where any system operating parameter falls outside established safe operating limits, resulting, or likely to result, in unstable operation, operation outside of design limits, or potential release.

Task Analysis:

A method for determining the detailed performance required of people and equipment and determining the effects of the surroundings, malfunctions, and other unexpected events on both.

Task:

A meaningful unit of work with a measurable value that contains more than two steps and has a clearly defined starting and stopping point.

Task List:

A list identifying and cataloging tasks performed by a job position or job area through research, analysis, and observation. Task List information may supply the base for the development of written procedures. A Task List can also be the product of a Task Analysis.

Validation:

The act of testing the completeness and accuracy of a written procedure by observing a user perform or simulate the task.

CHAPTER 1

INTRODUCTION TO EFFECTIVE PROCEDURE WRITING

1.1. Why Was This Book Written?

Pick up a dictionary and find the entry for procedure. One definition is: a particular course or mode of action. A simple statement, but to procedure users, writers, and managers concerned with process safety, the word procedure implies much more. The Center for Chemical Process Safety’s approach to Process Safety Management relies on written procedures to document both hands-on operations and maintenance activities as well as to describe the Process Safety Management system itself. This book was written to help select and implement actions that will

Help reduce accidentsPromote safe, efficient operation and maintenanceImprove quality, continuity, profitability, and cost controlBuild upon and record process experienceHelp maintain your competitive edgeReflect the best thinking on how to safely operate and manage your facilityComply with governmental regulations or industrial initiatives requiring written proceduresPromote the idea that operating and maintenance procedures are vital plant components

The last item, treating procedures as if they were equipment (just like a pump, valve, reactor, or safety system), is fundamental for building a successful Process Safety Management system. Who would start up a new process without all of the pumps in place and tested? What craftsperson would tackle a pump seal replacement without the required tools and parts? By accepting this idea, that procedures are components, the concepts presented in this book will naturally fall into place.

Effectively written procedures can help to ensure the smooth startup of a new process or help solve a tricky problem. A large company with many sites can share procedures between plants with similar processes. A single site can gain by capturing temporary or seldom performed activities on paper for future use. Reinventing the wheel takes time that is better spent on productive activities.

Developing written procedures forces you to analyze your process, resulting in a better understanding of how to improve it. Safer, more efficient operations and maintenance follow, resulting in enhanced quality, decreased downtime, and lower costs.

Will effective procedures guarantee that your plant can avoid all accidents? No, they won’t and they can’t. However, as a component of your process safety management system, effective use of procedures can reduce the number of accidents caused by human error. Sound management practices encourage written procedures, and regulations now demand them for many processes. The purpose of this book is to make your procedure-writing efforts as productive as possible and to create accurate, effective procedures.

1.2. Book Objectives

There are three objectives for this book. Keep them in mind as you use this book. This book will

Guide readers in developing effective written procedures to operate and maintain both large and small facilitiesEncourage development of procedure management systems that involve the users, emphasize control of the procedures, and require management and employee commitment to procedure use, accessibility, training, and management of changeHelp procedure writers produce effective, usable procedures that support safe and efficient operations and maintenance through improved communication

1.3. The Current Worldwide Trend Toward Procedures

Operating and maintenance procedures have become an international issue. Europe, Canada, and the United States have all issued or proposed regulations that require procedures for process safety purposes. Industry groups supporting offshore oil exploration have also recognized the value of procedures to improve process safety. The International Organization for Standardization (ISO) includes the control and use of procedures as a key element of a company’s quality management system. These influences affect more companies each year as they seek a global market for their products.

In the United States, the impact of the Occupational Safety and Health Administration’s (OSHA) Rule 29 CFR 1910.119 “Process Safety Management of Highly Hazardous Chemicals; Explosives and Blasting Agents; Final Rule” and/or the Environmental Protection Agency’s (EPA) Proposed Rule 40 CFR Part 68 “Risk Management Programs for Chemical Accidental Release Prevention” is already being felt. Developing, training on, and maintaining the required written operating and maintenance procedures is a significant effort. This work represents a major and critical share of the total compliance effort these regulations demand. Your written procedures link the human component to the process.

Even before these regulations existed, groups such as the American Institute of Chemical Engineers’ Center for Chemical Process Safety (CCPS), the Institution of Chemical Engineers (IChE), the Chemical Manufacturers Association (CMA), and the American Petroleum Institute (API) all promoted written procedures as a sound management practice. This practice, if firmly held, can lead to improved plant safety and product quality. Table 1-1 lists some organizations and documents that recommend or require procedures.

TABLE 1-1Organizations and Documents Recommending or Requiring Procedures

ORGANIZATIONDOCUMENTAIChE Center for Chemical Process Safety (AIChE/CCPS)Guidelines for Technical Management of Chemical Process Safety, AIChE/CCPS, New York, New York 1989.American Petroleum Institute (API)API Recommended Practice 750, Management of Process Hazards, American Petroleum Institute, Washington, DC, 1990.Chemical Manufacturers Association (CMA)Responsible Care®: A Public Commitment, Chemical Manufacturers Association, Washington, DC, 1988.U.S. Environmental Protection Agency (EPA)Risk Management Programs for Chemical Accidental Release Prevention; Proposed Rule 40 CFR part 68, Environmental Protection Agency, Washington, DC, 1993.International Organization for Standardization (ISO) or in the United States of America American National Standards Institute (ANSI) 9000-1, 9001, 9002, 9003, 9004-1Quality Management and Quality Assurance Standards (9000) ISO 9000-ISO 9004,Quality Systems—Models for Quality Assurance (9001-9003)Quality Management and Quality System Elements—Guidelines (9004)International Organization for Standardization, Geneva, Switzerland 1987.US Occupational Safety and Health Administration, US Department of Labor (OSHA)Process Safety Management of Highly Hazardous Chemicals; Explosives and Blasting Agents; Final Rule 29 CFR 1910.119, Occupational Safety and Health Administration, Washington, DC, 1992.Organization for Economic Cooperation and Development (OECD)Workshop on Prevention of Accidents Involving Hazardous Substances Good Management Practice, Discussion Document Relating to the Development of OECD Guideline for the Prevention of Accidents Involving Hazardous Substances, Organization for Economic Cooperation and Development, Berlin, 1989.Official Journal of the European CommunitiesCouncil Directive of 24 June 1982 (the Seveso Directive) on the Major-Accident Hazards of Certain Industrial Activities, Official Journal of the European Communities, Berlin, 1989.The World BankManual of Industrial Hazard Assessment Techniques, The World Bank, Washington, DC 1985.

Whether a guideline, a regulation, or a recommended practice and whether for process safety, environmental, or quality reasons, a strong operating and maintenance procedure system will benefit your company.

1.4. Who Should Use This Book?