Problem, Failure and Safety Analysis of Ammonia Plant: a ...
Ammonia Process Safety Managementbfff.co.uk/.../2015/...Safety-Management_16052017.pdfSafe...
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Safe Management of Ammonia Refrigeration Systems – May 2017 in Grantham
Ammonia Process Safety Management
Mark Roxburgh
Mercury Technologies Ltd.
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PSM – What is it?
Set of tools for managing a hazardous process
Hardware & Procedures
Preventive & Reactive
It is an ongoing programme
Not a “Snapshot” risk assessment
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PSM – The Tools
1. Information 2. Mechanical integrity 3. Operating procedures 4. Training 5. Employee participation 6. Incident investigation 7. Management of change 8. Non-routine work authorisations 9. Contractors 10. Emergency response 11. Pre-commissioning review 12. Review 13. Hazard analysis
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1. Information...
MSDS
Flow diagrams & P&IDs
Drawings
Press/temp limits posted
Test certificates
Manuals
Load and charge calculations
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2. Mechanical integrity...Major hardware
Inspections – each item of hardware
Daily log
PM
PSSR
Calibrations
Manuals up-to-date
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2. Mechanical integrity...peripheral hardware
Ventilation
Ammonia detection
Beacons & alarms
Relief valves
Signage, labels, tags
PPE
Building layout, lighting
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3. Operating procedures...
Start & stop, normal & emergency
Oil drain
Charging
LOTO
Confined space
Opening the system
Ammonia leak
First aid
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4. Training...
Operation & maintenance
Ammonia awareness
Emergency response teams
Use of PPE
Evacuation
Spills
Refreshers for ALL
Records kept?
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5. Employee participation...
Is the a system in place to communicate safety information across the facility?
Are all level of employees involved?
Is information readily available to all
Are there clear channels of communications
Televisions
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6. Incident investigation...
System in place?
Begin in a timely manner
Team make-up – contractor
Report
Implementation of recommendations
Further actions
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7. Management of change...
Changes approved by all parties
Time enough for change
H&S impact investigated
Procedures modified
PM modified
Training modified
Safety hardware modified
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8. Non-routine work authorisations...
Permit to work
Is a system in place?
Relevant to ammonia
Monitored and recorded
Time, date, place
Hot work
Fire prevention
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9. Contractors...
Provide them H&S information
They provide you H&S information
Training
Induction
Monitoring
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10. Emergency response...
Is there a plan?
Is there a team?
Instructions for all groups?
Communication
Training – drills
First aid
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10. Emergency response...
Plume modelling Extent and severity AEGLs
Plant room leak Pressure relief valve Major outdoor spill
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10. Emergency response - AEGLs
AEGL-1 is the airborne concentration, expressed as parts per million ormilligrams per cubic meter (ppm or mg/m3) of a substance above which it ispredicted that the general population, including susceptible individuals,could experience notable discomfort, irritation, or certain asymptomaticnon-sensory effects. However, the effects are not disabling and aretransient and reversible upon cessation of exposure.
AEGL-2 is the airborne concentration (expressed as ppm or mg/m3) of asubstance above which it is predicted that the general population, includingsusceptible individuals, could experience irreversible or other serious, long-lasting adverse health effects or an impaired ability to escape.
AEGL-3 is the airborne concentration (expressed as ppm or mg/m3) of asubstance above which it is predicted that the general population, includingsusceptible individuals, could experience life-threatening health effects ordeath.
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10. Emergency response - AEGLs
AEGL-1 reversible upon cessation of exposure
AEGL-2 irreversible and/or impaired ability to escape
AEGL-3 death
10min 30min 60min 4hr 8hr
AEGL-1 30 30 30 30 30
AEGL-2 220 220 160 110 110
AEGL-3 2,700 1,600 1,100 550 390
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10. Emergency response...
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10. Emergency response...
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10. Emergency response...
Modify hardware accordingly
Feedback into emergency response plans
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10. Emergency response...
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10. Emergency response...
Detailed responses for all groups Full response documentation file
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11. Pre-commissioning...
As many of these risk management tools in place as possible
Design DSEAR RA, HA and OCA outputs in place
Testing, NDT approved
Commissioning procedures approved
Site awareness
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12. Reviews...
1yr – 2 yr – 3yr
Following significant changes
Following significant events
Procedure used - relevant
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13. Hazard analysis...
Various techniques• HAZOP – Hazard and Operability Analysis
• FMEA – Failure Mode and Effects Analysis
• FTA – Fault Tree Analysis
• Checklist
• What-If
• What-If Checklist best suited
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13. Hazard analysis...
Each major item of equipment
Human factors
Site issues
Instrumentation
Shutdown/Start-up
Emergency situations
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13. Hazard analysis...
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13. Hazard analysis...
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Finally...
Since DSEAR makes reference to many of the above, a DSEAR risk assessment can now be carried out