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 types-
Source, 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 Annual Maintenance Contract
 CCA Cause Consequence Analysis
 CCPS Centre for Chemical Process Safety
 DCS Distributed Control System
 EHS Environment, Health & Safety
 FLP Flameproof
 FMEA Failure Mode and Effects Analysis
 FRLS Fire Resistant Low Smoke
 HAZOP Hazard Operability
 HR Heat Resistant
 HRA Human Reliability Analysis
 IDLH Immediately Dangerous to Life & Health
 IP Ingress Protection
 LOP Loss of Profit
AL
 MOC Material of Construction
 MTBF Mean Time Between Failure
 MTO Material Transfer Order
 NDT Non Destructive Testing
 O&M Operation & Maintenance
 OEM Original Equipment Manufacturer
 OSEP On Site Emergency Plan
 P & ID Piping & Instrumentation Diagram
 PDCA Plan Develop Check and Act
 PEME People, Environment, Materials, Equipment
 PHA Process Hazard Analysis
 PLC Programme Logic Controller
 PM Preventive Maintenance
AL

 R&D Research & Development

 RCA Root Cause Analysis
 SCADA Supervisory Control and Data Acquisition
 SHE Safety, Health & Environment
 SOP Standard Operating Procedure
 ZH Zero Halogen

Source credits: Publications, Experiences,

Professional contributions,
Interactions with Chemical Industry,OEMs.