Bonus Report Safety Developments M.A. TURK and A. MISHRA, Invensys Operations Management, Houston, Texas Process safety management: Going beyond functional safety ities re become me Modern bydcatbon proces 6 incemingly moe compere the tik nm pea cetyl ‘Etemed Enc the ity tempopes, th ernment sopiysal lint suetein the event ofan enepected oes ‘cunion cnet sett. The development fnew ‘gue and ecco designe eimpror operational i {yh eraled tome ther challenges Operating companies Me incesnng flrs ode thea of eaatopic event ‘chaste lest ft eee or explo ena at ‘in damage he coven pat sey, eel ese Injury or dens eplges snd the eer ees ROAD TO IMPROVING PLANT SAFETY Tish Sloe er ‘Efort to improve plant safety were led by state-of heart facto sty sums Tete roms eral the dey Shtdowe freer its whe snarl t tbat are beyond the epi othe op Whi fnctonal sey tas proven sues eng the probity of cape wet and coger he ale fan etry t der ao expel aes the yes ene ad bec yore mtn oe ‘Sonal tg od potable perormon of psc pane Inti contest stare the proaches that operating come ‘es shoud ato go baynd anol ify fo preety ‘Desun monitor ad apy lt pot in ste sero smprove proces mafey prormane ‘Why invest ne and resource og beyond thei tion of fncionl salty? To snore qerton, we mas nd ler ana oe ithe pc nd oye) at i om potential cstatopc evens, What ae {he expres fc osabisbing 4 PSM cre long with {ging implementngand mating prose PSM | tenet ting en ye HISTORY OF SAFETY MANAGEMENT SYSTEMS Asti nd chology rogeeedin the ely stop he plant ing est 30 people ad Spprorinatly 700 house nea Tir explosion Piaating per won sed elup the torge leo 50/50 mine of smmonr ste ad mont tte. Thisprcedar hed preven been wed 15000 (es witht espe leslie sponse to thee nen THteeningy the US Cones for Chere Proces Salty (€PS), wh provides leadership and thot and adance PSM, opts pe ey wot Bo ‘heb ofthe Brandywine Riverine ary ayo 9 entry at Ed Pts ack powde works Reognang thar eens enil cient old precptate conser Ja esd los of fe de oot edhe workable ad ‘psa ender ery spect onda nds ‘Torcmemory here fist of seen een jr ada tal nate ih ie conmeguncee imme tet may bef T18t—Newco City Mes Aa 20 atone) song wth 20 ills + 8b Norsy Lacie Abyvexbonvapor oud trove $400 lon damages Tn Toe9Pasaken, Tete An etene/uobatene ep sion td ie camed 23 ale 130 juried ore han Sich ett aft incite damaged the pb ond ‘heaviest They ao cased spat conics In "espns goerment contin nation and pose es focused on eng the ebay fre events ie tre opeatng compan femed silted comers Uh inde snp of pose stomtion teshnalogy The (pals to only auton stone ht anes oper [igcompines tao arte sy eens he ly ‘dco nd conocion, Arve by meet fy cote ‘Stsophoy ch solos ane ot ben ently set The preset sate thet salty mamgementtcades salty ties (HAZID, AZO, et aa) salty iste ‘ened sytem (680 ean gu decom an emerge ‘Fshldowey abnor son nanpenect sles snd pero pda iol Aste nr the eeSafety Developments stp in implementing foconl fey stems th woot ‘lpn ad oncapil dng beh + mer th Miecbedcateeterne pomeranian car Scere and tose te batescope fh project Work then poctde to desop te dtl fr he SIS. The signe of eta ae (OPA) eSpecting ety nstumentd faction (SI) and preporingthe ry eguremets specication (SR) pets Devopng the sy tng level (SIL) reese worst and port duced pote resin dog the roby ote get proceso ares hy ar er ate, HAEOP sie) or racve (eg, emergency sbutlown te) eT proonsoe ese htpeed by en Eeindcaton tata ell Thre abaye = ccnion af hing tat ents nen shown the Swi chee tod (3) enchecked yes wal eters ot finn and napalm can cc en efoto erecta ses concuneey inet, the ole inthe Sarees model Dome ges Withoot sting odin alginic xe cit contl ye ‘Stn ag inte awl be reeled they ac belle important aren def ‘urerour recent high role tse ve heightened the yasnes te tons need ay more ein te pce ny By en, proce et St engiering and anogeret hh oad on preventing ‘uotopbieseddens anes ts—prtilyexpoons wr aly (PHA) aod layers satay as ep) a = fexand damaging relat aid th he sf conti tof ecg or nar eons chan checlsand pele procs These engioring and management shill exceed those sued for mining the wore Asindutal neste Ser oa te cbs of ee 1 Lipton pine copontenssedinddls 1 Inceed srt by elton goverment sock pce in fome cies, even when execavet and maogen hire prion proces ety, hing slg wrong. Too fen, restr, o without proper contest or xfer iran ‘ins gt tbe sity opr plant personnel et eating prove acionable norman aout te lt {ateaon of key opening snd seyret prsatare Rema Toenialyheudows eons can be averted whet Feorting tos plant por anespency shown, Tris the [aloft noes prt genetton stoma sone ied at making sep change impovemest in salty peor. Sch tome can powdery ery mrtg a [itslaveidance ston Ths shoo be a enetalermpo Byway of dsintion PSM sth sppesionofanagemnet syria to ey endeand an cov proce ha thar preventing grocstd nies and incest The ot nine process nents by evan the wale [roe PS cane to widespread ner the sdopion of Stn Standard 29 CER 1910119 Prac Saety Mangement {fig Hazards Chain 1990. PSM coer Proce sft informaton 1 imple ivobement pa + Opening precedes + Me aaron of change+ Incident ivetigon + Hinegency lng ad expanse + Campencesae Another dino of PSM i “he practve sd sete asc identcsion enon and miigton or preston of ‘hemlet cold acu ae fires po ‘sen, proedes or eglent" FSM tnd ce caplet + Elson Fe. 3ehowt where PSM fs int the ove con tentofopertion neg (keeping the proces fs the pape, an how fneina sky ey le Business cae for PSM. A co/bnet c Contes toda Se mets oe ae | Senet neg! yon sna ‘itaten mages plea, ae be ee itp to mf ogni rues and ma Iie ope Fe seo tt ly eis teepueneto’ atin SM so Pose toy made Fee be den Sane vag {cesmaneremorceet re p a ‘Sings sen ora bd pode ey, | spt dey ge nina Chon sel eA cee ‘thea campos ened neo he oan fem ae chon DESIGN ANO FRAMEWORK FORA PM SYSTEM ated heparan Vides a8 opportanty wo aosd major Incidents a acca mse Safety Developments sed to show plant salty and opines peng on ons. etre management or arses pos treapprosch rik anagenent nan con tat scaly re operating ed ssl Leng Indestor that an cf tik contre cong ee eae) hydrocarbon age, petroleum refining and Peete eee Cusicy Pee ee in ee ctl very dangerous if not managed correctly, essay performance ist oid ngounastorncthat ake ‘2 sng aque contood Diets sr mgs ted to one tt efectnenen finer con age ner rats For poole nr snd pthc mn carry proce sly ae» sia pct ob des et nga ny pat ‘edits This bute noematon ater a fo eins eusingflores char ets a mas Thovelnoiednmanasnproce sty eth * What conta aren lace to prevent orients? {What der ach contol dvr interme ay ou sine pete Measuring perlrmance before a catastrophe tau. According 1 Jer Reson our) stents alt ne 2 ioron al ngs itl ker tent Intel consent? Each i centr san ess ‘importa! beer o ged within fe PSS pen, ASafety Developments gna ling in ust oe thai maybe icine ‘pre n foamjor sceken. Conic mens std mutoring te atl eaine performance of thee st) un emures that penton ep o compromieed dheto dagrsaton fbi cag al aging initors ve ein stracured and sysctl central ste win the Tle PSM ose anda hey a at tom gens, Proving dl saan to confirm tat th skcontal {eis cpetinga intended or providing = wasing at prob lemessetarting to el Tending inary tan acne motoring form ose on fw kcotr syrems oes contin ef theese Lenigindst rege a one ptt check thay acon actives unraenantended- They be Conideted se mesure of rots mp sential to ‘ie the dient ooo Thelen en {ang oben apes coveted ring rutne {heck om the opera «els wa the “Lagging indicators are sstve monitoring mtd auic he pring tad iesigaton of ie oct Fncdents or events do ot hae to result n mor damage o iar ere ns continent, proidng hey epesent wale of pcan contol sym a guard agus lathe onsucices fs mornin aging iia ‘Sw wena deed ty tome hat ed ors 0 Ben scised Te gging incr revealing ot “oles So {fathered illowing sn neato aves event ‘vironmental dmg ae ean be anes a precursor ‘tentormandee once tba to Eling hat SBecontl tem Seve erpitons and sands recomend oping seg nd bn ie rt ao + 154840004 Recommended Practices or Guidlines for Anlenentatin of ANSY/I 8400012004 (IEC 1ST! Med) Instone eon stom = -=) — GelSafety Developments imation thatanbeusedtoprevencaastopicerens Wha fect, proce ty KPs cn provide an ext waring ‘npusaton hs amenting HSE ce PSM maybe tht cool have detested ance lee ‘eet to bencimu plete famed orto cay outs ‘Meaarng performance ora how efi ie Tskaenmenty the expecatons ofeach len and ens beingcontae ian eae partofan HSE sytem Ths can ipanyanpetslthe esi este hat ay ned eaancig, _beactompled ia two ays implimentng sacha Po tem elites the funds: + Active aneioring. provides Gedback on pastor tion fs FSM conta lop’ lates sch contr man baie nt indent Toop to prevent compen rom crenig te ooatlty"'v Reaetie monitoring, I isles Mening and 1e fncaaophic ot daca lot pesonnel igang portngon nents to check th the contrast pace a 32 {nd aging nd about Geataton of protection lees unto dently wetness gp in conta ster and rove by sk conta oop. ‘ler tom tates ‘During plant operations stem ar modified to aap 10 ‘hechanpagestem esdsSyeneandprocdurscin dete SPIS and incremental valueatrisk. Afr 3 set of KP ture tie andre tres dence llowinge mi. hav bon adopted, heat wes managment repo Jorincentfeqoenty surprseseiormanages whiney sear montring ete KP and eaponinge devon Eiichi conte were fanctoningwdegnod Used fom thle snes. At gh uanagemen ey thee franc ofthe KPe oid wih naan la sumer = ‘Sine lose Therefore Secmer near 0 alte he owote Indvidal equgeat level KP snd ther bsies impaction vets Sren | BE | 5 | M85 |) tele perfomance ndeatrs apd ta bate i Weaee | age | Weaet || Skinpupperanagementtandentand the qalty of PSM re | on | Shame | Meme | Ma |) Sorte ccrpise Se ee a Ung tenia egument KP, atewapproah allows ee) . » 5 {nd economic impact on theses adion, this ap ows sid tothe ing LOPA snd socal imp an "KPLanercr ate athered bse on tease ower matage mn eles et mento te pla exuipment elit a employes sd oe ‘See fllone to args prooesnlty.Typealy 10-20 lay ‘Sets cae coveed ond cde mamapenent fete os ue || a inedenuapment (eg. complton opto Bld devee roo ‘et ssoated wails dition columns) 2) competence not personne eg tht eto tna se sl ten), nea >fala 5) dene netted proces (eg strate ier gts) a eden eg, inalement fade a tod fal sty even) These metice cn sia fom management tacoma yer eoetion (LOR) a level (eg. SS)orttbeline of gpm evel (lender) 8. amo of rat ceo The ft perfomance indo (SPs gration sé the inde! KPIs ito singe ube Ei. lon lee fe nstats the ower i 60 suno1an | marron conSafety Developments Cleating the weighted KPI fora protection layer. The KPL fr aLOP can becuse 1EP_LOP = Wight erage KP ofp of protection [err = ey pesmi itor rested te plant, pros people Gs ppttle) sc Number KPIs fran LOP Tider fr eunting sbe f KP ode fr cuting amber FLOPS, Calculating safety performance indo for equlpment Caner theses of equipment Bar «number of LOP From asfety pups the LOPs se of diferent impor tance andece ro the LOPA, each ana ted redaction foe The weighted KP ected a theeguipent in be ages and weihtod ong hee ‘elon aor aed ith hw LOP ot_zon_SoSafxxer_von, Saatind ya sor_noun, eo 1 Name aes of rtecton lop Weight lier of protection = RRE forthe per {lie fronting LOP nex for counting nner of pleceroFeqipment Calculating safety performance Index for 9 tectity Cader tat a acity hun 9 LOEe Erm ty penpectne LOES at of diflrent nortan levee Fonte LODA each LOE is asolted witht ep Inet sk, The SPs forthe LORS can be agregatd ing the {Sal factor eet fhe LOA Dh ee —F, ser_pranr = EQRSK ag ask 62 sarc rete where: Tanderared count the pice of eq intheplant 2Q_ USK = Tt mitated ier apes of pment SALBLANT "SP forthe pant Estimatod losses associated with LOE risk and plat Based onthe Sasa perfonoance sate canbe cle Forex the cate ngor och good (> 959), tring [98 to 988) and tad (e 90).Atocted ‘ned wnt ests ty permanente fect (xpeced a) fat con be ceed wing te SF, Theat prtomanc eat athe sepa Tor erp th crea sn ae ik tinted a lo 10% of est ore ste he ‘Sy patomance sates dterintobe al Sof he ‘ert esr alors the sy performace dtr ‘Mnes te wring Obl the sor eat i te ‘Sy perfomance dnermind tbe ood TE Esme ements ma J plintlerelinemetlasiet aloe at akcanbeestinatd ‘yedding teense increta set aera ko the ots with the clit Tho pet oa inceena prod Wale sk con be etal by ang the nermentl po. hction vor tsk th undeyng ies of eqpmet at tina incremental st et =D vorincnent atest Pat: mated intl roduc cpacy ks lace production pact an SP > 90% aca corporation wth many lant the incremental ast heatithand he pada noo kens Be agreed ae Crpntin Etmatencrmmtl Ast eta Plt reenter oi Conor: Esimaedinceenta peda apy = Patines at ae ate Dashboards. To dap he Pande ncementl eset worst betel pcos ow oes TetscL Sinn nn snd plat el coord lull dpa the pant fy perfomance dat ahd pode {Tikdnwr palin bevndsyngKPeoraaya ofthe Sinleying cee denied de Onc etd rect plot canbe defied ad ipl ns taly anne ol coy sano yetSafety Developments Best practices and lessons learned s proven sha Pe and Panchen Maa Spechg sod mabtang ec ps nal sytem apd decide onthe ode and PL actos, Step 9. Establish mangement roles acts of, Seta luc ato and ena “ction tosses FP Partner with the Best Wilh ove 50 independent ssn tes ened mere han 220 engineering tnd tales offices spread aos the wrod, SAMSON ensures the softy tnd ecvronmersl competi af yur plots on any content Te fer the fll ange ighrevely contol equips wie stil processes, SAMSON es. brovght osha highly speci compa rie for the SAMSON GROUP Sano Mn Caen (aw rorove Qn ‘STAR LM overec