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Guidelines for Integrating Process Safety into Engineering Projects

Guidelines for Integrating Process Safety into Engineering Projects

Autorzy
Wydawnictwo John Wiley & Sons Inc
Data wydania 2019
Liczba stron 432
Forma publikacji książka w twardej oprawie
Poziom zaawansowania Dla profesjonalistów, specjalistów i badaczy naukowych
Język angielski
ISBN 9781118795071
Kategorie Inżynieria: pojęcia ogólne
664.65 PLN (z VAT)
$149.51 / €142.50 / £123.70 /
Produkt na zamówienie
Dostawa 5-6 tygodni
Ilość
Do schowka

Opis książki

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.

Guidelines for Integrating Process Safety into Engineering Projects

Spis treści

List of Figure xvii





List of Tables xviii





Acronyms and Abbreviations xx





Glossary xxviii





Acknowledgments xxxii





Files on the Web xxxiv





Preface xxxvi





1 INTRODUCTION 1





1.1 Background and Scope 2





1.2 Why Integrating Process Safety is Important 3





1.3 What Type of Projects Are Included? 5





1.4 Project Life Cycle 7





1.5 Relationship to Other Programs 10





1.6 Structure of this Document 13





2 PROJECT MANAGEMENT CONCEPTS AND PRINCIPLES 16





2.1 Common Principles and Structure 16





2.1.1 Statement of Requirements 16





2.1.2 Project Scope 17





2.1.3 Basis of Design 17





2.1.4 Project Budget 18





2.1.5 Project Plan 18





2.1.6 Project Life Cycle 19





2.2 Project Management 20





2.3 Project Governance 21





2.4 Types of Project 22





2.4.1 Greenfield Projects 22





2.4.2 Brownfield Projects 22





2.4.3 Retrofit / Expansion Projects 23





2.4.4 Control System Upgrade Projects 24





2.4.5 Demolition Projects 24





2.4.6 Management of Change Projects 24





2.4.7 Mothballing Projects 25





2.4.8 Re-Commissioning Projects 25





2.4.9 Restarting a Project 25





2.4.10 Post-Incident Projects 26





2.5 Project Organization 26





2.5.1 Pre-Project Team 26





2.5.2 Typical Project Team 27





2.5.3 Unit Based Team 28





2.5.4 Equipment Based Team 28





2.5.5 Site Based Team 28





2.5.6 Small Projects 28





2.5.7 Roles and Responsibilities 29





2.6 Strategies for Implementation 32





2.6.1 Contractor Selection 35





2.6.2 Engineering Only 36





2.6.3 Engineering and Procurement 36





2.6.4 Engineering, Procurement and Construction 36





2.6.5 Operation 37





2.6.6 Contractor Oversight 37





2.7 Risk Management 38





2.8 Project Controls 40





2.8.1 Planning and Progress 40





2.8.2 Estimates, Budgets and Cost Control 41





2.8.3 Reporting 41





2.8.4 Metrics 41





2.8.5 Action Tracking 42





2.8.6 Change Management 42





2.9 Other Considerations 43





2.9.1 Materials Management 43





2.9.2 Quality Management 43





2.9.3 Lessons Learned 43





2.9.4 Post-Project Close-Out 44





2.10 Stage Gate Reviews 44





3 FRONT END LOADING 1 46





3.1 Preliminary Hazard Identification 48





3.2 Preliminary Inherently Safer Design Review 49





3.3 Concept Risk Analysis 51





3.4 Other Activities 52





3.4.1 Process Safety and EHS Plan 52





3.4.2 Risk Register 52





3.4.3 Action Tracking 52





3.5 Stage Gate Review 53





3.6 Summary 54





4 FRONT END LOADING 2 56





4.1 Evaluation of Development Options 58





4.1.1 Hazard Identification 59





4.1.2 Preliminary Inherently Safer Design Review 59





4.1.3 Concept Risk Analysis 60





4.1.4 Selection of the Development Option 60





4.2 Further Definition of the Selected Option 63





4.2.1 Design Hazard Management Process 63





4.2.2 Preliminary Inherently Safer Design (ISD) 68





4.2.3 Hazard Identification and Risk Analysis (HIRA) 68





4.2.4 Engineering Design Regulations, Codes, and Standards 69





4.2.5 Design Philosophies/Strategies 70





4.2.6 Preliminary Facility Siting Study 71





4.2.7 Preliminary Fire and Explosion Analysis 72





4.2.8 Transportation Studies 72





4.2.9 Preliminary Blowdown and Depressurization Study 74





4.2.10 Preliminary Fire & Gas Detection Study 74





4.2.11 Preliminary Fire Hazard Analysis 74





4.2.12 Preliminary Firewater Analysis 75





4.2.13 Preliminary Security Vulnerability Analysis 75





4.2.14 Other Engineering Design Considerations 75





4.3 Other Activities 76





4.3.1 EHS and Process Safety Plan 76





4.3.2 Risk Register 76





4.3.3 Action Tracking 76





4.3.4 HIRA Strategy 76





4.3.5 Docum entation 77





4.3.6 Stage Gate Review 77





4.4 Summary 79





5 FRONT END LOADING 3 80





5.1 Evaluation of Development Options 82





5.2 Further Definition of the Selected Option 82





5.2.1 Design Hazard Management Process 84





5.2.2 Inherently Safer Design Optimization 85





5.2.3 Facility Siting and Layout 86





5.2.4 Refine Design Safety Measures 93





5.2.5 Set Performance Standards 94





5.2.6 Hazard Identification and Risk Analysis (HIRA) 95





5.2.7 Safety Assessments 102





5.2.8 Re-Evaluate Major Accident Risk 113





5.2.9 Finalize Important Safety Decisions 113





5.2.10 Finalize Basis of Design 113





5.3 Other Engineering Considerations 114





5.3.1 Asset Integrity Management 114





5.3.2 Quality Management 115





5.3.3 Contractor Selection 115





5.3.4 Brownfield Developments 116





5.4 Other Activities 116





5.4.1 EHS and Process Safety Plans 116





5.4.2 Risk Register 116





5.4.3 Action Tracking 116





5.4.4 Change Management 116





5.4.5 Documentation 117





5.4.6 Preparation for Project Execution 117





5.5 Case for Safety 119





5.6 Stage Gate Review 119





5.7 Summary 120





6 DETAILED DESIGN STAGE 121





6.1 Detailed Design 124





6.1.1 Design Hazard Management Process 124





6.1.2 Inherently Safer Design Optimization 125





6.1.3 Site Layout 126





6.1.4 Design Safety Measures 126





6.1.5 Set Performance Standards 127





6.1.6 Hazard Identification and Risk Analysis (HIRA) 127





6.1.7 Safety Assessments 128





6.1.8 Re-Evaluate Major Accident Risk 129





6.1.9 Other Design Reviews 129





6.2 Procurement 130





6.3 Asset Integrity Management 131





6.4 Other Process Safety Activities 132





6.4.1 Case For Safety 132





6.5 Other Project Activities 133





6.5.1 EHS and Process Safety Plans 133





6.5.2 Risk Register 134





6.5.3 Action Tracking 134





6.5.4 Change Management 134





6.5.5 Documentation 135





6.5.6 Constructability 136





6.5.7 Contractor Selection 137





6.6 Preparation for Construction 138





6.7 Preparation for Pre-Commissioning, Commissioning, and Startup 139





6.8 Stage Gate Review 140





6.9 Summary 141





7 CONSTRUCTION 143





7.1 Planning 146





7.2 Pre-Mobilization 147





7.3 Mobilization 149





7.4 Execution 150





7.4.1 Procurement 151





7.4.2 Fabrication 151





7.4.3 Safety Culture 151





7.4.4 Workforce Involvement 152





7.4.5 Stakeholder Outreach 152





7.4.6 Contractor Management 152





7.4.7 Transportation 153





7.4.8 Equipment and Materials Handling 153





7.4.9 Hazard Evaluation 154





7.4.10 Engineering Design 156





7.4.11 Safe Work Practices 157





7.4.12 Operating, EHS and Process Safety Procedures 159





7.4.13 Training and Competence Assurance 159





7.4.14 Asset Integrity Management 160





7.4.15 Change Management 161





7.4.16 Emergency Response 162





7.4.17 Incident Investigation 163





7.4.18 Auditing 164





7.4.19 Performance Measurement 164





7.4.20 Operations Case for Safety 165





7.4.21 Pre-Commissioning 166





7.4.22 Mechanical Completion 170





7.4.23 Documentation 171





7.5 Other Project Activities 172





7.5.1 EHS and Process Safety Plans 172





7.5.2 Risk Register 172





7.5.3 Action Tracking 172





7.5.4 General Construction Management 172





7.6 De-Mobilization 173





7.7 Preparation for Commissioning and Startup 174





7.8 Final Evaluation and Close-out 175





7.9 Stage Gate Review 175





7.10 Summary 177





8 QUALITY MANAGEMENT 178





8.1 Design/Engineering 183





8.2 Procurement 186





8.3 Fabrication 187





8.4 Receipt 189





8.5 Storage and Retrieval 190





8.6 Construction and Installation 191





8.7 Operation 193





8.8 Documentation 194





8.9 Summary 194





9 COMMISSIONING AND STARTUP 196





9.1 Preparation 199





9.1.1 Planning 199





9.1.2 Safety 201





9.2 Operational Readiness 202





9.2.1 Pre-Startup Stage Gate Review 203





9.2.2 Operational Readiness Review 204





9.2.3 Start-Up Efficiency Review 207





9.3 Commissioning 208





9.3.1 Equipment Testing 209





9.3.2 Commissioning Procedures 211





9.4 Startup 213





9.4.1 Preparation for Startup 213





9.4.2 Calibration of Instruments and Analyzers 213





9.4.3 Startup with Process Chemicals/Fluids 214





9.5 Common Process Safety Elements 215





9.5.1 Hazard Evaluation 215





9.5.2 Safe Work Practices 216





9.5.3 Procedures 217





9.5.4 Training and Competence Assurance 217





9.5.5 Management of Change 218





9.5.6 Incident Investigation 219





9.5.7 Emergency Response 220





9.5.8 Auditing 221





9.5.9 Documentation 221





9.5.10 Performance Measurement 222





9.6 Other Project Activities 222





9.6.1 EHS and Process Safety Plans 222





9.6.2 Risk Register 223





9.6.3 Action Tracking 223





9.7 Performance Test Runs 223





9.8 Handover 224





9.9 Preparation for Ongoing Operation 225





9.10 Project Close-Out 226





9.10.1 Close Out Report 226





9.10.2 Post-Project Evaluation 226





9.11 Summary 227





10 OPERATION 228





10.1 Process Safety Management System 231





10.1.1 Process Safety Culture 233





10.1.2 Compliance with Standards 233





10.1.3 Process Safety Competency 233





10.1.4 Workforce Involvement 234





10.1.5 Stakeholder Outreach 234





10.1.6 Process Knowledge Management 234





10.1.7 Hazard Identification and Risk Analysis 234





10.1.8 Operating Procedures 235





10.1.9 Safe Work Practices 235





10.1.10 Asset Integrity and Reliability 236





10.1.11 Contractor Management 238





10.1.12 Training and Performance Assurance 239





10.1.13 Management of Change 239





10.1.14 Operational Readiness 239





10.1.15 Conduct of Operations 240





10.1.16 Emergency Management 240





10.1.17 Incident Investigation 240





10.1.18 Measurement and Metrics 241





10.1.19 Auditing 242





10.1.20 Management Review and Continuous Improvement 242





10.1.21 EHS and Process Safety Procedures 243





10.2 Other Project Activities 243





10.2.1 EHS and Process Safety Plans 243





10.2.2 Risk Register 243





10.2.3 Action Tracking 243





10.3 Technical Support 243





10.4 Performance Test Runs 244





10.5 Operation Stage Gate RFview 244





10.6 Post-Operational Review 245





10.7 Project Close-Out 246





10.8 Summary 246





11 END OF LIFE 247





11.1 Design for Decommissioning 249





11.2 Planning for Decommissioning 250





11.2.1 Engineering Survey 251





11.2.2 Hazard Evaluation 254





11.2.3 Hazardous Materials 254





11.2.4 Process Safety Plan 255





11.2.5 Utilities 255





11.2.6 Re-Engineering 256





11.3 Decommissioning Procedures 256





11.3.1 Late-Life Operations 257





11.3.2 Cessation of Production 258





11.3.3 Cleaning and Decontamination 258





11.3.4 Mothballed Facilities And Equipment 258





11.4 Deconstruction and Demolition 259





11.4.1 Deconstruction 259





11.4.2 Demolition 260





11.5 Process Safety for Decommissioning 261





11.5.1 Contractor Management 261





11.5.2 Safety Culture 262





11.5.3 Workforce Involvement 263





11.5.4 Stakeholder Outreach 263





11.5.5 Hazard Evaluation 263





11.5.6 Safe Work Practices 264





11.5.7 EHS and Process Safety Procedures 265





11.5.8 Training and Competence Assurance 266





11.5.9 Asset Integrity Management 267





11.5.10 Change Management 267





11.5.11 Operational Readiness Review 267





11.5.12 Emergency Management 268





11.5.13 Incident Investigation 269





11.5.14 Auditing 269





11.5.15 Disposal 270





11.5.16 Remediation 270





11.6 Other Project Activities 271





11.6.1 EHS and Process Safety Plans 271





11.6.2 Risk Register 271





11.6.3 Action Tracking 271





11.6.4 General Decommissioning Management 272





11.6.5 Stage Gate Reviews 272





11.7 Summary 274





12 DOCUMENTATION 275





12.1 Document Management 275





12.2 Process Knowledge Management 278





12.2.1 Front End Loading 1 Stage 278





12.2.2 Front End Loading 2 Stage 279





12.2.3 Front End Loading 3 Stage 280





12.2.4 Detailed Design Stage 281





12.2.5 Construction Stage 283





12.2.6 Commissioning and Startup Stage 286





12.2.7 Handover 287





12.2.8 Operation Stage 288





12.2.9 End of Life Stage 291





12.3 Summary 292





APPENDIX A. TYPICAL PROCESS SAFETY STUDIES OVER PROJECT LIFE CYCLE 293





APPENDIX B. PROJECT PROCESS SAFETY PLAN 295





APPENDIX C. TYPICAL HAZARD & RISK REGISTER 298





APPENDIX D. SAFETY CHECKLIST FOR PROCESS PLANTS 301





APPENDIX E. EXAMPLE OF SITE-SPECIFIC DECOMMISSIONING CHECKLIST / QUESTIONNAIRE 315





APPENDIX F. TYPICAL PROJECT DOCUMENTATION 322





APPENDIX G. STAGE GATE REVIEW PROTOCOL FOR PROCESS SAFETY 337





REFERENCES 365





INDEX 379

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