Preparing for a Successful HAZOP/LOPA (Making or Breaking Quality & Efficiency)

Transcription

1 Preparing for a Successful HAZOP/LOPA (Making or Breaking Quality & Efficiency) (GCPS-2018 Paper ) Steven T. Maher, PE CSP / Carine M. Black / John M. Johnson 949/

2 Steven T. Maher, PE CSP 38-Year Engineer 34 in Process Safety Consulting Specializing in Hazard Analysis and QRA Mechanical Engineering BS Duke University MS Carnegie-Mellon University Professional Engineer Mechanical & Chemical Engineering CCPS Technical Steering Committee mid-1980s Past-President Southern CA Society for Risk Analysis Landmark Efforts Platform Safety Shutdown System Effectiveness Study Torrance Refinery Safety Advisor for MHF Conversion Paper & Book Publications See

3 Carine M. Black Chemical Engineer University of California, Santa Barbara Extensive HAZOP/LOPA Scribe Support CalARP / RMP / PSM Program Development Auditing P&ID Development Dispersion Modeling Webinar / Presentation Speaker on RMP / PSM Related Issues

4 Preparing for a Successful HAZOP/LOPA (Making or Breaking Quality & Efficiency) (GCPS-2018 Paper ) Steven T. Maher, PE CSP / Carine M. Black / John M. Johnson 949/

5 Key Topics Importance of a Quality PHA PHA History and Regulatory Requirements Defining Objectives and Approach HAZOP/LOPA Planning Tips HAZOP/LOPA Preparation Tips HAZOP/LOPA Venue Tips Final Readiness Tips Summary Questions

6 Why is a Quality Process Hazard Analysis Important Tragedies to Avoid

7 Brief History of Key PHA Techniques and Regulatory Requirements

8 Evolution of SMS Guidelines & Regulations to Performance (Goal) Based Standards Onshore Process Safety (USA) Offshore Safety Management Systems (USA) Offshore Safety Management Systems (UK)

9 HAZOP & LOPA are Core Elements of Hazard Evaluation Significant Damage due to Fire / Explosion LV-1 or Bypass Open Protection Layers (OP Action, Control Sys, Prot Sys) LV-1 Malfunctions Open LT/LIC-1 Fails High Bypass Valve Inadvertently Open by Operator Operator Response to Alarm Fails Pressure Relief Failure Null Alarm Fails to Annunciate LT/LIC-1 Fails High Operator PSV-1 PSV-2 Fails to Fails to Open Fails to Open Respond to on Demand on Demand Alarm Flange Leakage Null Vessel Failure HAZOP LOPA What-If CHAZOP FMECA Checklist

10 Defining Objectives and Approach

11 General Objectives Identify potential safety, environmental, or operability issues. Recommend vulnerability corrections and document bases. Provide training to personnel. Provide background and bases for the safety programs & procedures.

12 Approach Can Vary Quality Team Utilization & Effectiveness Session Time Capital Projects vs. Operating Facilities

13 HAZOP/LOPA Planning Tips

14 Timeline for PHA Planning/Preparation Week 7 Week 6 Week 5 Week 4 Week 3 Week 2 Week 1 PHA Study Team Invitation & Schedule* Define Objectives and Scope* Conduct Final Des. Review* P&ID Walkdown / Field Verification* Arrange PHA Venue* Determine PHA Tools Arrange for PHA Meeting Equipment* Begin Preparing PHA Elements Resolve Final Des. Review Items (if applicable)* Pre-load Risk Ranking Matrix, Design Intentions & Consequence Categories, Deviation Matrix & Template Final P&ID / PFD / C&E Revisions* Define Sections (Nodes) Populate Causes Training & Reference Materials P&ID / PFD Copies*

15 Key Disciplines Useful for a Facilitation/Leadership (R) Team Scribe/Recorder HAZOP/LOPA Process/Project Engineering (R) Operations (R) Maintenance (R) Control/Protection Instrumentation Engineer HSE Engineering Rotating Equipment Specialists Specialists to Address Unique Requirements, e.g., DMR, SPA, HCA (R = Required by PSM/RMP)

16 Planning Tips - Scribe Quality Scribe Support is Essential Familiarity with HAZOP/LOPA techniques Familiarity with reading engineering drawings Familiarity with the software Scribe Support Cost-Balance With Scribe Without Scribe

17 HAZOP/LOPA Preparation Tips

18 Key Information Requirements Process Flow Diagrams Piping & Instrumentation Diagrams (with changes identifiable from any previous HAZOP Studies) Cause & Effect Diagrams Alarm & PSV Setpoints Site Layout / Platform Location Drawings Access to All Other Process Safety Information

19 Beware of Common Design Information Gaps P&ID Information Content Control Valves Relief Valves Pumps Block Valves

20 Be Prepared to Discuss Details Heat Exchangers/Coolers General Process Condition Changes Instrumentation Electric Immersion Heaters Other (primarily applicable for lube oil systems) Tanks

21 HAZOP/LOPA Venue Tips

22 General Venue Tips Venue Location Team Member Distribution & Room Set-up Venue Amenities

23 Including Remote HAZOP/LOPA Team Members Adequate Computers/Displays Arrange Communications Access and IT Support Power and Communications Connections for All Computer Equipment Verify sufficient communications bandwidth!!! Verify that equipment is contemporary. Cameras Testing

24 Final Readiness Tips

25 Final Readiness Pre-define and Communicate Causes Completeness Future Use Quickly locating Equipment on P&ID During Session Grouping Causes Pre-define and Communicate Questions P&ID Grid Format

26 Summary

27 Success = Planning + Preparation Optimize Quality & Efficiency! Capital Projects Optimize process design Minimize design and operation costs Minimize start-up challenges Operating Facilities Mitigate risks Minimize vulnerabilities Address regulatory requirements

28 Success = Planning + Preparation Advance Scheduling Team members Optimal venue Obtain/Develop Necessary PSI Initial causes/questions Maximize HAZOP/LOPA Investment!

29 Questions? Steven T. Maher, PE CSP Carine M. Black 877/