Safety In Chemical And Hydrocarbon Process Industry --change Management

Key focus areas in Chemical Process industry  Change and Equipment Management are key

ELEMENTS in Process Safety System.  Some of the World’s “News splash incidents” have involved Change Management as focal point  Equipment Management is no less important  Change Management should follow appropriate Process Hazard Analysis  CCPS is an excellent reference for proper application of Process Hazard Evaluation Techniques

Hazard Evaluation Techniques Guideline for Hazard Evaluation Procedure –Buy CCPS Book Typical Techniques mentioned  Safety review  Checklists  Relative Ranking  Preliminary Hazard Analysis  What –If , What-If checklist  HAZOP  FMEA  FTA  ETA  CCA  HRA

Change Management-Essentials  Change need driver  Criteria for Change : SHE, IDLH, Life

threatening, Insurance, Legal, Statutory items should get priority attention  Change initiation procedure publication  Prescribing Change processing steps  Determining Change review Team composition  Validating Change acceptance criteria  Sign off protocol in Change approval checklist

Preceding Activity.  Change Planning should focus on PEME  Change organising should list -Preceding

/Succeeding activity  Change control, MOC,Conformance to Codes, Fabrication qualification , Inspection typesSource, Incoming,On-site, Material Spec, OEM Spec sheets,Deviation control/Approval are key aspects before Change implementation  Change validation should be tested by PDCA prior to Change confirmation as Permanent  Change benefit evaluation is necessary

Succeeding Activities Change revision Confirmation SOP Revision. OSEP Review Re-training Re-certification of Trained personnel P.M. List Update Isometrics, P & ID, related Doc Update Spares Identification, Inventory stipulation

Contd.. Payout tracking Archiving database

Equipment Management—Book keeping

 MOC  Fabrication details, Related drawings, Isometrics  Flanges, Gaskets, Nuts, Bolts, Piping, Bends, Elbows,

Fittings, Insulation-- Specifications Sheet  FLP/IP/FRLS/HR /ZH/--DCS, PLC, SCADA  Built-in Safety devices/features  List of Codes/Standards adopted  MTO  Installation qualification  Process/Operational qualification including HAZOP study  Final qualification—ID, Asset entry, Insurance

Documentation/Maintenance

         

Deliverables Statutory SOP O &M Manuals OEM-Recommended Spares Spares Management kardex P.M. List/NDT Schedule Work instructions History card MTBF Charts

Performance Support Needs

 List of Lubricants  Supply Sources—Qualifications of Suppliers –      

Criteria AMC/Warranty Trade supports—Electrical, Instrumentation, EHS,Engg Performance trending Run Log Inspection-Sensorial, Instrumentation (Speed, Vibration, Fatigue, Noise, Heat and such) NDT-Methodology, Monitoring Tools

Breakdown-Impact review aids

 Incident log and reports  Macro Interruptions  Micro interruptions  RCA, Component reliability analysis  Recovery Time  Impact analysis—Economic/Customer impact  Insurance Cover—Fire/Allied, Machinery Break

down, LOP, Natural/Security perils, Human contributory

Conclusion  Change involves thinking holistically  Change may necessitate downtime  Interruption due to incidents can affect safety of

personnel and Business economics.  Each change review should be situation specific.  General references cannot displace internal Multi-disciplinary review and validation.  Yet changes can become necessary to continually improve Safety, Health & Environment

Abbreviations List -AL              

AMC CCA CCPS DCS EHS FLP FMEA FRLS HAZOP HR HRA IDLH IP LOP

Annual Maintenance Contract Cause Consequence Analysis Centre for Chemical Process Safety Distributed Control System Environment, Health & Safety Flameproof Failure Mode and Effects Analysis Fire Resistant Low Smoke Hazard Operability Heat Resistant Human Reliability Analysis Immediately Dangerous to Life & Health Ingress Protection Loss of Profit

AL             

MOC MTBF MTO NDT O&M OEM OSEP P & ID PDCA PEME PHA PLC PM

Material of Construction Mean Time Between Failure Material Transfer Order Non Destructive Testing Operation & Maintenance Original Equipment Manufacturer On Site Emergency Plan Piping & Instrumentation Diagram Plan Develop Check and Act People, Environment, Materials, Equipment Process Hazard Analysis Programme Logic Controller Preventive Maintenance

AL  R&D  RCA  SCADA  SHE  SOP  ZH

Source credits:

Research & Development Root Cause Analysis Supervisory Control and Data Acquisition Safety, Health & Environment Standard Operating Procedure Zero Halogen Publications, Experiences, Professional contributions, Interactions with Chemical Industry,OEMs.