Ammonia Process Safety Management

Transcription

1 Ammonia Process Safety Management Mark Roxburgh Mercury Technologies Ltd. Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham

2 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 Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 2

3 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 Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 3

4 1. Information... MSDS Flow diagrams & P&IDs Drawings Press/temp limits posted Test certificates Manuals Load and charge calculations Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 4

5 2. Mechanical integrity... Major hardware Inspections each item of hardware Daily log PM PSSR Calibrations Manuals up-to-date Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 5

6 2. Mechanical integrity... peripheral hardware Ventilation Ammonia detection Beacons & alarms Relief valves Signage, labels, tags PPE Building layout, lighting Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 6

7 3. Operating procedures... Start & stop, normal & emergency Oil drain Charging LOTO Confined space Opening the system Ammonia leak First aid Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 7

8 4. Training... Operation & maintenance Ammonia awareness Emergency response teams Use of PPE Evacuation Spills Refreshers for ALL Records kept? Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 8

9 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 Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 9

10 6. Incident investigation... System in place? Begin in a timely manner Team make-up contractor Report Implementation of recommendations Further actions Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 10

11 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 Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 11

12 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 Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 12

13 9. Contractors... Provide them H&S information They provide you H&S information Training Induction Monitoring Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 13

14 10. Emergency response... Is there a plan? Is there a team? Instructions for all groups? Communication Training drills First aid Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 14

15 10. Emergency response... Plume modelling Extent and severity AEGLs Plant room leak Pressure relief valve Major outdoor spill Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 15

16 10. Emergency response - AEGLs AEGL-1 is the airborne concentration, expressed as parts per million or milligrams per cubic meter (ppm or mg/m 3 ) of a substance above which it is predicted that the general population, including susceptible individuals, could experience notable discomfort, irritation, or certain asymptomatic non-sensory effects. However, the effects are not disabling and are transient and reversible upon cessation of exposure. AEGL-2 is the airborne concentration (expressed as ppm or mg/m 3 ) of a substance above which it is predicted that the general population, including susceptible individuals, could experience irreversible or other serious, longlasting adverse health effects or an impaired ability to escape. AEGL-3 is the airborne concentration (expressed as ppm or mg/m 3 ) of a substance above which it is predicted that the general population, including susceptible individuals, could experience life-threatening health effects or death. Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 16

17 10. Emergency response - AEGLs AEGL-1 AEGL-2 AEGL-3 reversible upon cessation of exposure irreversible and/or impaired ability to escape death 10min 30min 60min 4hr 8hr AEGL AEGL AEGL-3 2,700 1,600 1, Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 17

18 10. Emergency response... Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 18

19 10. Emergency response... Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 19

20 10. Emergency response... Modify hardware accordingly Feedback into emergency response plans Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 20

21 10. Emergency response... Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 21

22 10. Emergency response... Detailed responses for all groups Full response documentation file Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 22

23 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 Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 23

24 12. Reviews... 1yr 2 yr 3yr Following significant changes Following significant events Procedure used - relevant Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 24

25 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 Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 25

26 13. Hazard analysis... Each major item of equipment Human factors Site issues Instrumentation Shutdown/Start-up Emergency situations Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 26

27 13. Hazard analysis... Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 27

28 13. Hazard analysis... Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 28

29 Finally... Since DSEAR makes reference to many of the above, a DSEAR risk assessment can now be carried out Safe Management of Ammonia Refrigeration Systems May 2017 in Grantham Slide 29