Guidelines for Integrating Process Safety into Engineering Projects

Inbunden, Engelska, 2019

Av CCPS (Center for Chemical Process Safety), Ccps (Center for Chemical Process Safety, CCPS, Ccps (Center For Chemical Process Safety)

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There is much industry guidance on implementing engineering projects and a similar amount of guidance on Process Safety Management (PSM). However, there is a gap in transferring the key deliverables from the engineering group to the operations group, where PSM is implemented. This book provides the engineering and process safety deliverables for each project phase along with the impacts to the project budget, timeline and the safety and operability of the delivered equipment.

Produktinformation

Utgivningsdatum2019-01-18
Mått158 x 231 x 25 mm
Vikt839 g
FormatInbunden
SpråkEngelska
Antal sidor432
Upplaga1
FörlagJohn Wiley & Sons Inc
ISBN9781118795071

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Teknik: allmänt inom Naturvetenskap och teknik

Since 1985, the Center for Chemical Process Safety (CCPS) has been the global leader in developing and disseminating information on process safety management and technology. CCPS, an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has published over 100 books in its process safety guidelines and process safety concepts series, and over 100 training modules through its Safety in Chemical Engineering Education (SACHE) series.

List of Figure xviiList of Tables xviiiAcronyms and Abbreviations xxGlossary xxviiiAcknowledgments xxxiiFiles on the Web xxxivPreface xxxvi1 INTRODUCTION 11.1 Background and Scope 21.2 Why Integrating Process Safety is Important 31.3 What Type of Projects Are Included? 51.4 Project Life Cycle 71.5 Relationship to Other Programs 101.6 Structure of this Document 132 PROJECT MANAGEMENT CONCEPTS AND PRINCIPLES 162.1 Common Principles and Structure 162.1.1 Statement of Requirements 162.1.2 Project Scope 172.1.3 Basis of Design 172.1.4 Project Budget 182.1.5 Project Plan 182.1.6 Project Life Cycle 192.2 Project Management 202.3 Project Governance 212.4 Types of Project 222.4.1 Greenfield Projects 222.4.2 Brownfield Projects 222.4.3 Retrofit / Expansion Projects 232.4.4 Control System Upgrade Projects 242.4.5 Demolition Projects 242.4.6 Management of Change Projects 242.4.7 Mothballing Projects 252.4.8 Re-Commissioning Projects 252.4.9 Restarting a Project 252.4.10 Post-Incident Projects 262.5 Project Organization 262.5.1 Pre-Project Team 262.5.2 Typical Project Team 272.5.3 Unit Based Team 282.5.4 Equipment Based Team 282.5.5 Site Based Team 282.5.6 Small Projects 282.5.7 Roles and Responsibilities 292.6 Strategies for Implementation 322.6.1 Contractor Selection 352.6.2 Engineering Only 362.6.3 Engineering and Procurement 362.6.4 Engineering, Procurement and Construction 362.6.5 Operation 372.6.6 Contractor Oversight 372.7 Risk Management 382.8 Project Controls 402.8.1 Planning and Progress 402.8.2 Estimates, Budgets and Cost Control 412.8.3 Reporting 412.8.4 Metrics 412.8.5 Action Tracking 422.8.6 Change Management 422.9 Other Considerations 432.9.1 Materials Management 432.9.2 Quality Management 432.9.3 Lessons Learned 432.9.4 Post-Project Close-Out 442.10 Stage Gate Reviews 443 FRONT END LOADING 1 463.1 Preliminary Hazard Identification 483.2 Preliminary Inherently Safer Design Review 493.3 Concept Risk Analysis 513.4 Other Activities 523.4.1 Process Safety and EHS Plan 523.4.2 Risk Register 523.4.3 Action Tracking 523.5 Stage Gate Review 533.6 Summary 544 FRONT END LOADING 2 564.1 Evaluation of Development Options 584.1.1 Hazard Identification 594.1.2 Preliminary Inherently Safer Design Review 594.1.3 Concept Risk Analysis 604.1.4 Selection of the Development Option 604.2 Further Definition of the Selected Option 634.2.1 Design Hazard Management Process 634.2.2 Preliminary Inherently Safer Design (ISD) 684.2.3 Hazard Identification and Risk Analysis (HIRA) 684.2.4 Engineering Design Regulations, Codes, and Standards 694.2.5 Design Philosophies/Strategies 704.2.6 Preliminary Facility Siting Study 714.2.7 Preliminary Fire and Explosion Analysis 724.2.8 Transportation Studies 724.2.9 Preliminary Blowdown and Depressurization Study 744.2.10 Preliminary Fire & Gas Detection Study 744.2.11 Preliminary Fire Hazard Analysis 744.2.12 Preliminary Firewater Analysis 754.2.13 Preliminary Security Vulnerability Analysis 754.2.14 Other Engineering Design Considerations 754.3 Other Activities 764.3.1 EHS and Process Safety Plan 764.3.2 Risk Register 764.3.3 Action Tracking 764.3.4 HIRA Strategy 764.3.5 Docum entation 774.3.6 Stage Gate Review 774.4 Summary 795 FRONT END LOADING 3 805.1 Evaluation of Development Options 825.2 Further Definition of the Selected Option 825.2.1 Design Hazard Management Process 845.2.2 Inherently Safer Design Optimization 855.2.3 Facility Siting and Layout 865.2.4 Refine Design Safety Measures 935.2.5 Set Performance Standards 945.2.6 Hazard Identification and Risk Analysis (HIRA) 955.2.7 Safety Assessments 1025.2.8 Re-Evaluate Major Accident Risk 1135.2.9 Finalize Important Safety Decisions 1135.2.10 Finalize Basis of Design 1135.3 Other Engineering Considerations 1145.3.1 Asset Integrity Management 1145.3.2 Quality Management 1155.3.3 Contractor Selection 1155.3.4 Brownfield Developments 1165.4 Other Activities 1165.4.1 EHS and Process Safety Plans 1165.4.2 Risk Register 1165.4.3 Action Tracking 1165.4.4 Change Management 1165.4.5 Documentation 1175.4.6 Preparation for Project Execution 1175.5 Case for Safety 1195.6 Stage Gate Review 1195.7 Summary 1206 DETAILED DESIGN STAGE 1216.1 Detailed Design 1246.1.1 Design Hazard Management Process 1246.1.2 Inherently Safer Design Optimization 1256.1.3 Site Layout 1266.1.4 Design Safety Measures 1266.1.5 Set Performance Standards 1276.1.6 Hazard Identification and Risk Analysis (HIRA) 1276.1.7 Safety Assessments 1286.1.8 Re-Evaluate Major Accident Risk 1296.1.9 Other Design Reviews 1296.2 Procurement 1306.3 Asset Integrity Management 1316.4 Other Process Safety Activities 1326.4.1 Case For Safety 1326.5 Other Project Activities 1336.5.1 EHS and Process Safety Plans 1336.5.2 Risk Register 1346.5.3 Action Tracking 1346.5.4 Change Management 1346.5.5 Documentation 1356.5.6 Constructability 1366.5.7 Contractor Selection 1376.6 Preparation for Construction 1386.7 Preparation for Pre-Commissioning, Commissioning, and Startup 1396.8 Stage Gate Review 1406.9 Summary 1417 CONSTRUCTION 1437.1 Planning 1467.2 Pre-Mobilization 1477.3 Mobilization 1497.4 Execution 1507.4.1 Procurement 1517.4.2 Fabrication 1517.4.3 Safety Culture 1517.4.4 Workforce Involvement 1527.4.5 Stakeholder Outreach 1527.4.6 Contractor Management 1527.4.7 Transportation 1537.4.8 Equipment and Materials Handling 1537.4.9 Hazard Evaluation 1547.4.10 Engineering Design 1567.4.11 Safe Work Practices 1577.4.12 Operating, EHS and Process Safety Procedures 1597.4.13 Training and Competence Assurance 1597.4.14 Asset Integrity Management 1607.4.15 Change Management 1617.4.16 Emergency Response 1627.4.17 Incident Investigation 1637.4.18 Auditing 1647.4.19 Performance Measurement 1647.4.20 Operations Case for Safety 1657.4.21 Pre-Commissioning 1667.4.22 Mechanical Completion 1707.4.23 Documentation 1717.5 Other Project Activities 1727.5.1 EHS and Process Safety Plans 1727.5.2 Risk Register 1727.5.3 Action Tracking 1727.5.4 General Construction Management 1727.6 De-Mobilization 1737.7 Preparation for Commissioning and Startup 1747.8 Final Evaluation and Close-out 1757.9 Stage Gate Review 1757.10 Summary 1778 QUALITY MANAGEMENT 1788.1 Design/Engineering 1838.2 Procurement 1868.3 Fabrication 1878.4 Receipt 1898.5 Storage and Retrieval 1908.6 Construction and Installation 1918.7 Operation 1938.8 Documentation 1948.9 Summary 1949 COMMISSIONING AND STARTUP 1969.1 Preparation 1999.1.1 Planning 1999.1.2 Safety 2019.2 Operational Readiness 2029.2.1 Pre-Startup Stage Gate Review 2039.2.2 Operational Readiness Review 2049.2.3 Start-Up Efficiency Review 2079.3 Commissioning 2089.3.1 Equipment Testing 2099.3.2 Commissioning Procedures 2119.4 Startup 2139.4.1 Preparation for Startup 2139.4.2 Calibration of Instruments and Analyzers 2139.4.3 Startup with Process Chemicals/Fluids 2149.5 Common Process Safety Elements 2159.5.1 Hazard Evaluation 2159.5.2 Safe Work Practices 2169.5.3 Procedures 2179.5.4 Training and Competence Assurance 2179.5.5 Management of Change 2189.5.6 Incident Investigation 2199.5.7 Emergency Response 2209.5.8 Auditing 2219.5.9 Documentation 2219.5.10 Performance Measurement 2229.6 Other Project Activities 2229.6.1 EHS and Process Safety Plans 2229.6.2 Risk Register 2239.6.3 Action Tracking 2239.7 Performance Test Runs 2239.8 Handover 2249.9 Preparation for Ongoing Operation 2259.10 Project Close-Out 2269.10.1 Close Out Report 2269.10.2 Post-Project Evaluation 2269.11 Summary 22710 OPERATION 22810.1 Process Safety Management System 23110.1.1 Process Safety Culture 23310.1.2 Compliance with Standards 23310.1.3 Process Safety Competency 23310.1.4 Workforce Involvement 23410.1.5 Stakeholder Outreach 23410.1.6 Process Knowledge Management 23410.1.7 Hazard Identification and Risk Analysis 23410.1.8 Operating Procedures 23510.1.9 Safe Work Practices 23510.1.10 Asset Integrity and Reliability 23610.1.11 Contractor Management 23810.1.12 Training and Performance Assurance 23910.1.13 Management of Change 23910.1.14 Operational Readiness 23910.1.15 Conduct of Operations 24010.1.16 Emergency Management 24010.1.17 Incident Investigation 24010.1.18 Measurement and Metrics 24110.1.19 Auditing 24210.1.20 Management Review and Continuous Improvement 24210.1.21 EHS and Process Safety Procedures 24310.2 Other Project Activities 24310.2.1 EHS and Process Safety Plans 24310.2.2 Risk Register 24310.2.3 Action Tracking 24310.3 Technical Support 24310.4 Performance Test Runs 24410.5 Operation Stage Gate Rview 24410.6 Post-Operational Review 24510.7 Project Close-Out 24610.8 Summary 24611 END OF LIFE 24711.1 Design for Decommissioning 24911.2 Planning for Decommissioning 25011.2.1 Engineering Survey 25111.2.2 Hazard Evaluation 25411.2.3 Hazardous Materials 25411.2.4 Process Safety Plan 25511.2.5 Utilities 25511.2.6 Re-Engineering 25611.3 Decommissioning Procedures 25611.3.1 Late-Life Operations 25711.3.2 Cessation of Production 25811.3.3 Cleaning and Decontamination 25811.3.4 Mothballed Facilities And Equipment 25811.4 Deconstruction and Demolition 25911.4.1 Deconstruction 25911.4.2 Demolition 26011.5 Process Safety for Decommissioning 26111.5.1 Contractor Management 26111.5.2 Safety Culture 26211.5.3 Workforce Involvement 26311.5.4 Stakeholder Outreach 26311.5.5 Hazard Evaluation 26311.5.6 Safe Work Practices 26411.5.7 EHS and Process Safety Procedures 26511.5.8 Training and Competence Assurance 26611.5.9 Asset Integrity Management 26711.5.10 Change Management 26711.5.11 Operational Readiness Review 26711.5.12 Emergency Management 26811.5.13 Incident Investigation 26911.5.14 Auditing 26911.5.15 Disposal 27011.5.16 Remediation 27011.6 Other Project Activities 27111.6.1 EHS and Process Safety Plans 27111.6.2 Risk Register 27111.6.3 Action Tracking 27111.6.4 General Decommissioning Management 27211.6.5 Stage Gate Reviews 27211.7 Summary 27412 DOCUMENTATION 27512.1 Document Management 27512.2 Process Knowledge Management 27812.2.1 Front End Loading 1 Stage 27812.2.2 Front End Loading 2 Stage 27912.2.3 Front End Loading 3 Stage 28012.2.4 Detailed Design Stage 28112.2.5 Construction Stage 28312.2.6 Commissioning and Startup Stage 28612.2.7 Handover 28712.2.8 Operation Stage 28812.2.9 End of Life Stage 29112.3 Summary 292APPENDIX A. TYPICAL PROCESS SAFETY STUDIES OVER PROJECT LIFE CYCLE 293APPENDIX B. PROJECT PROCESS SAFETY PLAN 295APPENDIX C. TYPICAL HAZARD & RISK REGISTER 298APPENDIX D. SAFETY CHECKLIST FOR PROCESS PLANTS 301APPENDIX E. EXAMPLE OF SITE-SPECIFIC DECOMMISSIONING CHECKLIST / QUESTIONNAIRE 315APPENDIX F. TYPICAL PROJECT DOCUMENTATION 322APPENDIX G. STAGE GATE REVIEW PROTOCOL FOR PROCESS SAFETY 337REFERENCES 365INDEX 379