Process Safety Information (PSI) Standard

Transcription

1 Effective Date: On Date Approved Owned by: VP Enterprise Technical Reviewed every 5 years Livelink ID: Revision Approved: 2016/02/16 Controlled Document Copyright 2015 Suncor Energy Inc. All rights reserved. SUN of 15 Revision: 2.0

2 Summary of Changes This Summary shows: The location of each change within the document All changes to this document since it was last approved and published Location of Change Entire Document Summary of Change The entire PSI Standard has been re-written to fit the new GDF template. This document is the second revision of the Standard (first version: CO-S10A). Requirements changes in the new revision will be identified with a revision triangle beside it. SUN of 15 Revision: 2.0

3 Contents Summary of Changes...2 Contents About this Standard...4 Purpose...4 Scope...4 Target Audience...5 Conformance Expectations...5 Introduction Requirements Process Safety Information collection requirements...6 Overarching Requirements...6 Hazards of Materials...6 Technology of the Process...7 Equipment in the process Process Safety Information management requirements...11 Mechanisms of control Roles and Responsibilities...11 Business Area Senior Leader...11 Business Area PSI Leader...11 Technical Support Group Leaders...11 PHA Study Team Lead Measurement and Verification...12 Measurements...12 Verification Terms and Definitions References Essential Documents...14 SUN of 15 Revision: 2.0

4 1 About this Standard Purpose The purpose of this standard is to define the requirements for Suncor s Process Safety Information (PSI) for hazardous processes. PSI shall be complete, accurate, up to date and available to target users. Safe operation depends on individuals having accurate information readily available to make knowledgeable decisions. PSI enables individuals to identify hazards, evaluate risks and provides the basis for writing effective operating procedures, developing training and improving asset integrity. The PSI is the compilation of information related to the causes and mitigations used to prevent hazards arising from hazardous processes : Hazards of materials Technology of the process Equipment in the process The PSI standard also defines the process requirements for the control and communication of PSI, which include: Identification Storage Access Updates Retention Communication of PSI information Scope This Standard describes the PSI requirements for hazardous processes and includes the following information: Documents to be included in the PSI collection Document management control requirements for PSI Communication requirements of PSI A separate Process Safety Information Guideline (SUN DRAFT) document, associated with this standard, presents additional information intended to guide the Suncor sites in the process of creating and maintaining their PSI. SUN of 15 Revision: 2.0

5 Target Audience This Standard applies to Suncor Energy Inc. and subsidiaries over which Suncor has operational control (collectively Suncor or the company or enterprisewide ). This Standard does not apply to retail locations. As used in this document, Suncor personnel includes directors, officers, employees, contract workers, consultants and agents of Suncor. Conformance Expectations Conformance to all new and updated requirements in this standard is required within five years of the approval date. Where laws and regulations impose requirements not reflected in this Standard, the most stringent requirements shall apply. If a deviation to this Standard is required you must follow the GDF process. Introduction The Process Safety Information (PSI) is a compilation of the written information pertaining to the hazards of materials (raw materials, intermediates, wastes and finished products), process and equipment in every hazardous process. PSI enables all personnel involved in the operation and maintenance of the process to identify and understand the hazards, evaluate the risks and to make informed decisions, ensuring a safe operation. It is important that PSI is complete, accurate and available for all hazardous processes. The PSI is fundamental for activities such as development and use of operating procedures, training and asset integrity. SUN of 15 Revision: 2.0

6 2 Requirements 2.1 Process Safety Information collection requirements Overarching Requirements The following are the overarching requirements for Process Safety Information (PSI): The PSI shall include information related to three main categories : Hazards of materials Technology of the process Equipment in the process This Standard shall be implemented for all hazardous processes. The PSI shall be current, complete and reflect the facility s current condition before asset or plant start up. When equipment or materials are purchased with corresponding PSI, Suncor shall obtain the process design basis and other information from the vendor as well as the updated versions that may be published at later dates Hazards of Materials The following are the minimum requirements when compiling information related to Hazards of Materials Process safety information relating to the hazards of materials in the process must include: A Safety Data Sheet (SDS) table with the list of the SDS corresponding to all substances handled in the process. The Physical and chemical property data which is typically found in the SDS, as outlined below: Corrosivity Toxic exposure limits and guidelines Reactivity Flammability Thermal and chemical stability Additional physical or chemical properties of materials required to fully describe the hazard beyond what is included in the SDS. Chemical mixing/interaction matrix SUN of 15 Revision: 2.0

7 Technology of the Process The following outlines the minimum requirements when compiling PSI related to the Technology of the Process Process safety information related to the technology of the process must include: Required Information What to include Process flow diagrams Process chemistry description (including potential side or runaway reactions) Process steps Reaction explanation Heat and material balances Maximum intended inventory Equipment Design Basis Reports Process design basis Over Pressure Protection by System Design (OPPSD) requirements including: o Detailed analysis showing all possible credible overpressure scenarios o Assessment with the proof of system being self-limiting o Monitoring and mitigation measures for non-self-limiting systems: Monitoring measures (documented as an alarm or alert) Mitigation measures (documented as a safety instrumented function (SIF)) o OPPSD registration documentation if required by local jurisdiction Operating Envelope Safe Operating Limits (SOL) Standard Limits (SL) Include the consequences of exceeding these limits and any associated mitigation actions. SUN of 15 Revision: 2.0

8 Process Hazard Analysis (PHA) reports Risk Assessments Consequence analysis and facility siting (CA&FS) reports Layers of Protection Analysis (LOPA) reports SUN of 15 Revision: 2.0

9 Equipment in the process The following outlines the minimum requirements when compiling PSI related to the equipment in the Process Process Safety Information related to the equipment in the process shall include: Required Information Drawings What to include Piping and Instrument Diagrams (P&IDs) Area Classification Safety Plot plan with Fire Protection Equipment Fire and Gas Detection Layout Cause and Effect (Shut down key) diagrams and narratives Logic narratives Heating, Ventilation and Air Conditioned (HVAC) systems design o HVAC associated with PS critical equipment or structures o HVAC designed as occupational health and safety control. Mechanical Safety Systems Structural Design Basis, including all drawings and design calculations for: o Structural steel and foundations supporting process safety-critical equipment o Structures designed as safe havens. Data Sheets Instrument Data sheets Pressure Safety Valves (PSVs) data sheets and supporting calculations (PSV, relief devices (RD) and tank / vessel vents) Mechanical data sheets Lists Line Designation Table (LDT) Equipment lists Mechanical Safety Systems Valve Locking and Car Sealed Open Car Sealed Closed (CSO-CSC) lists SUN of 15 Revision: 2.0

10 Designation of Process Safety-Critical asset Safety Instrumented Systems (SIS): o Safety requirements specifications (SRS) report o SIF table o SIF validation and SIL verification report Process Interlocks (non-sis systems) Alarm and shutdown settings Lethal service designation table: o Sites which have lethal service designation shall provide a list of the equipment that are in lethal service as well as the assessment or calculations done to determine lethality. List of recognized and Generally Accepted Good Engineering Practices (RAGAGEP) as applicable to local jurisdictions, which include: o Suncor standards and guidelines Standard and Codes o Jurisdictional considerations (e.g. Alberta Boilers Safety Association (ABSA)). o Consensus codes and recommended industry practices and guidelines (e.g. American National Standards Institute (ANSI); American Petroleum Institute (API); National Fire Protection Association (NFPA), etc.) Materials of Construction and material selection diagram Reports Corrosion Hazard Review Reports and corrosion control documents Fire protection design Blast design Safe Haven design SUN of 15 Revision: 2.0

11 2.2 Process Safety Information management requirements Mechanisms of control The following are requirements for the control and communication of PSI: All process safety information shall be managed in compliance with the Asset Information Standards. Each site, supported by the PSI Leader, shall document any required access restrictions to the PSI, in accordance with the Information Sensitivity Standard (SUN-00196). Retention of PSI documents must be done following the Suncor Records Retention Schedule. 2.3 Roles and Responsibilities Business Area Senior Leader The Business Area Senior Leader shall: Ensure that personnel involved in activities with hazardous processes are familiar with the information in this Standard Provide support and resources to develop, update and maintain the PSI as per the requirements of this standard, for each hazardous process Assign a Business Area PSI Leader (or equivalent). This leader may be a single individual or a committee familiar with the hazardous process Ensure PSI is updated through the Management of Change Technical (MOC-T) process. Business Area PSI Leader The Business Area PSI Leader (or equivalent) shall: Ensure that the PSI (including PSI provided by vendors and contractors) is reviewed to confirm that it accurately represents the conditions in the field, is complete and available Technical Support Group Leaders The Technical Support Group Leaders shall: Support and provide resources for the development and documentation of the PSI. SUN of 15 Revision: 2.0

12 PHA Study Team Lead The PHA Study Team Lead shall: Ensure the PSI is updated according to the findings from the PHA study. 2.4 Measurement and Verification Measurements Verification The following are the minimum measures that will be tracked for this Standard: Business areas shall establish processes for review of Process Safety Information. The Business Area PSI Lead or equivalent will track these processes as they are developed The following criteria outline the verifications that the Process Safety Information Standard is being followed: Business Area PSI Leader or equivalent will verify that the PSI packages are complete and available Business Area PSI Leader or equivalent shall track the number of incidents / near misses related to lack of or faulty PSI These measures shall be reported by the OEMS Element 9 Driver on an annual basis to the Operations Council. SUN of 15 Revision: 2.0

13 3 Terms and Definitions Term Definition Retail As per North American Industry Classification System (NAICS) Canada, a retail trade sector comprises establishments primarily engaged in retailing merchandise, generally without transformation, and rendering services incidental to the sale of merchandise. The retailing process is the final step in the distribution of merchandise; retailers are therefore organized to sell merchandise in small quantities to the general public. This sector comprises two main types of retailers: Store retailers: oprate fixed poin-of-sale locations, located and designed to attract a high volume of walk-in customers. These include establishments such as office supplies stores, gasoline stations, etc. Non-store retailers: like store retailers, they are organized to serve the general public but the retailing methods differ. They reach customers and market merchandise with methods such as in-home domnstration, distribution by vending machines, temporary displaying of merchandise, etc. Pertinent terms are defined in a separate Definitions document: Process Safety Definitions document. SUN of 15 Revision: 2.0

14 4 References 4.1 Essential Documents The list below outlines the documents that need to be read with this document for full understanding: Document Number SUN CO-S19A Document Title Audit and Assessment Standard (in Draft at time of publication) Pre-Startup Review (PSSR) Standard CTS-0104 CTS-0126 Corporate Technical Standard Document Control of Engineering Records Sustained Information Requirements for Individual Assets CTS-0127 CTS-0128 Sustained Information Requirements for Asset Location and Use Corporate Technical Standard Asset Information Glossary CTS-0410 SUN (DRAFT) Corporate Technical Standard Safety Instrumented System Design PSI Guideline supports (best practices) the PSI Standard. MRS-GL-JSC- 001 Functional Safety Management Program for Safety Instrumented Systems SUN Governing Documents Framework- Part 1 - Standards SUN Consequence Analysis and Facility Siting Standard (CTS 2110) SUN SUN SUN SUN Process Hazard Analysis Standard (CO-S11A) Operating Envelope Standard Management of Change Standard (CO-S05) Risk Management Standard Suncor Process Safety Definitions Document CCPS: 29CFR (for U.S. facilities only) CCPS: 40CFR Part 68 (for U.S. facilities only) SUN of 15 Revision: 2.0

15 Livelink ID: Suncor Records Retention Schedule ASME Boiler & Pressure Vessel Code Link North American Classification System (NAICS) Canada, codes 44 and 45 SUN of 15 Revision: 2.0

16 The following individuals have approved and signed this document. UserName: Michael Krayacich (mkrayacich) Title: VP Enterprise Technical Date: Tuesday, 16 February 2016, 01:17 PM Mountain Time Meaning: I approve this document ================================================