Guidelines for Integrating Process Safety Into Engineering Projects

There is much industry guidance on implementing engineering projects and a similar amount of guidance on Process Safety Management (PSM). However, there is a gap in transferring the key deliverables from the engineering group to the operations group, where PSM is implemented. This book provides the engineering and process safety deliverables for each project phase along with the impacts to the project budget, timeline and the safety and operability of the delivered equipment. GUIDELINES FOR INTEGRATING PROCESS SAFETY INTO ENGINEERING PROJECTS......Page 3 Contents......Page 9 List of Figures......Page 19 List of Tables......Page 20 Acronyms and Abbreviations......Page 22 Glossary......Page 30 Acknowledgments......Page 34 Files on the Web......Page 36 Preface......Page 38 1 INTRODUCTION......Page 41 1.1 Background and Scope......Page 42 1.2 Why Integrating Process Safety is Important......Page 43 1.3 What Type of Projects Are Included?......Page 45 1.4 Project Life Cycle......Page 47 1.5 Relationship to Other Programs......Page 50 1.6 Structure of this Document......Page 53 2.1.1 Statement of Requirements......Page 56 2.1.3 Basis of Design......Page 57 2.1.5 Project Plan......Page 58 2.1.6 Project Life Cycle......Page 59 2.2 Project Management......Page 60 2.3 Project Governance......Page 61 2.4.2 Brownfield Projects......Page 62 2.4.3 Retrofit / Expansion Projects......Page 63 2.4.6 Management of Change Projects......Page 64 2.4.9 Restarting a Project......Page 65 2.5.1 Pre-Project Team......Page 66 2.5.2 Typical Project Team......Page 67 2.5.6 Small Projects......Page 68 2.5.7 Roles and Responsibilities......Page 69 2.6 Strategies for Implementation......Page 72 2.6.1 Contractor Selection......Page 75 2.6.4 Engineering, Procurement and Construction......Page 76 2.6.6 Contractor Oversight......Page 77 2.7 Risk Management......Page 78 2.8.1 Planning and Progress......Page 80 2.8.4 Metrics......Page 81 2.8.6 Change Management......Page 82 2.9.3 Lessons Learned......Page 83 2.10 Stage Gate Reviews......Page 84 3 FRONT END LOADING 1......Page 86 3.1 Preliminary Hazard Identification......Page 88 3.2 Preliminary Inherently Safer Design Review......Page 89 3.3 Concept Risk Analysis......Page 91 3.4.3 Action Tracking......Page 92 3.5 Stage Gate Review......Page 93 3.6 Summary......Page 94 4 FRONT END LOADING 2......Page 96 4.1 Evaluation of Development Options......Page 98 4.1.2 Preliminary Inherently Safer Design Review......Page 99 4.1.4 Selection of the Development Option......Page 100 4.2.1 Design Hazard Management Process......Page 103 4.2.3 Hazard Identification and Risk Analysis (HIRA)......Page 108 4.2.4 Engineering Design Regulations, Codes, and Standards......Page 109 4.2.5 Design Philosophies/Strategies......Page 110 4.2.6 Preliminary Facility Siting Study......Page 111 4.2.8 Transportation Studies......Page 112 4.2.11 Preliminary Fire Hazard Analysis......Page 114 4.2.14 Other Engineering Design Considerations......Page 115 4.3.4 HIRA Strategy......Page 116 4.3.6 Stage Gate Review......Page 117 4.4 Summary......Page 119 5 FRONT END LOADING 3......Page 120 5.2 Further Definition of the Selected Option......Page 122 5.2.1 Design Hazard Management Process......Page 124 5.2.2 Inherently Safer Design Optimization......Page 125 5.2.3 Facility Siting and Layout......Page 126 5.2.4 Refine Design Safety Measures......Page 133 5.2.5 Set Performance Standards......Page 134 5.2.6 Hazard Identification and Risk Analysis (HIRA)......Page 135 5.2.7 Safety Assessments......Page 142 5.2.10 Finalize Basis of Design......Page 153 5.3.1 Asset Integrity Management......Page 154 5.3.3 Contractor Selection......Page 155 5.4.4 Change Management......Page 156 5.4.6 Preparation for Project Execution......Page 157 5.6 Stage Gate Review......Page 159 5.7 Summary......Page 160 6 DETAILED DESIGN STAGE......Page 161 6.1.1 Design Hazard Management Process......Page 164 6.1.2 Inherently Safer Design Optimization......Page 165 6.1.4 Design Safety Measures......Page 166 6.1.6 Hazard Identification and Risk Analysis (HIRA)......Page 167 6.1.7 Safety Assessments......Page 168 6.1.9 Other Design Reviews......Page 169 6.2 Procurement......Page 170 6.3 Asset Integrity Management......Page 171 6.4.1 Case For Safety......Page 172 6.5.1 EHS and Process Safety Plans......Page 173 6.5.4 Change Management......Page 174 6.5.5 Documentation......Page 175 6.5.6 Constructability......Page 176 6.5.7 Contractor Selection......Page 177 6.6 Preparation for Construction......Page 178 6.7 Preparation for Pre-Commissioning, Commissioning, and Startup......Page 179 6.8 Stage Gate Review......Page 180 6.9 Summary......Page 181 7 CONSTRUCTION......Page 183 7.1 Planning......Page 186 7.2 Pre-Mobilization......Page 187 7.3 Mobilization......Page 189 7.4 Execution......Page 190 7.4.3 Safety Culture......Page 191 7.4.6 Contractor Management......Page 192 7.4.8 Equipment and Materials Handling......Page 193 7.4.9 Hazard Evaluation......Page 194 7.4.10 Engineering Design......Page 196 7.4.11 Safe Work Practices......Page 197 7.4.13 Training and Competence Assurance......Page 199 7.4.14 Asset Integrity Management......Page 200 7.4.15 Change Management......Page 201 7.4.16 Emergency Response......Page 202 7.4.17 Incident Investigation......Page 203 7.4.19 Performance Measurement......Page 204 7.4.20 Operations Case for Safety......Page 205 7.4.21 Pre-Commissioning......Page 206 7.4.22 Mechanical Completion......Page 210 7.4.23 Documentation......Page 211 7.5.4 General Construction Management......Page 212 7.6 De-Mobilization......Page 213 7.7 Preparation for Commissioning and Startup......Page 214 7.9 Stage Gate Review......Page 215 7.10 Summary......Page 217 8 QUALITY MANAGEMENT......Page 218 8.1 Design/Engineering......Page 223 8.2 Procurement......Page 226 8.3 Fabrication......Page 227 8.4 Receipt......Page 229 8.5 Storage and Retrieval......Page 230 8.6 Construction and Installation......Page 231 8.7 Operation......Page 233 8.9 Summary......Page 234 9 COMMISSIONING AND STARTUP......Page 236 9.1.1 Planning......Page 239 9.1.2 Safety......Page 241 9.2 Operational Readiness......Page 242 9.2.1 Pre-Startup Stage Gate Review......Page 243 9.2.2 Operational Readiness Review......Page 244 9.2.3 Start-Up Efficiency Review......Page 247 9.3 Commissioning......Page 248 9.3.1 Equipment Testing......Page 249 9.3.2 Commissioning Procedures......Page 251 9.4.2 Calibration of Instruments and Analyzers......Page 253 9.4.3 Startup with Process Chemicals/Fluids......Page 254 9.5.1 Hazard Evaluation......Page 255 9.5.2 Safe Work Practices......Page 256 9.5.4 Training and Competence Assurance......Page 257 9.5.5 Management of Change......Page 258 9.5.6 Incident Investigation......Page 259 9.5.7 Emergency Response......Page 260 9.5.9 Documentation......Page 261 9.6.1 EHS and Process Safety Plans......Page 262 9.7 Performance Test Runs......Page 263 9.8 Handover......Page 264 9.9 Preparation for Ongoing Operation......Page 265 9.10.2 Post-Project Evaluation......Page 266 9.11 Summary......Page 267 10 OPERATION......Page 268 10.1 Process Safety Management System......Page 271 10.1.3 Process Safety Competency......Page 273 10.1.7 Hazard Identification and Risk Analysis......Page 274 10.1.9 Safe Work Practices......Page 275 10.1.10 Asset Integrity and Reliability......Page 276 10.1.11 Contractor Management......Page 278 10.1.14 Operational Readiness......Page 279 10.1.17 Incident Investigation......Page 280 10.1.18 Measurement and Metrics......Page 281 10.1.20 Management Review and Continuous Improvement......Page 282 10.3 Technical Support......Page 283 10.5 Operation Stage Gate Review......Page 284 10.6 Post-Operational Review......Page 285 10.8 Summary......Page 286 11 END OF LIFE......Page 287 11.1 Design for Decommissioning......Page 289 11.2 Planning for Decommissioning......Page 290 11.2.1 Engineering Survey......Page 291 11.2.3 Hazardous Materials......Page 294 11.2.5 Utilities......Page 295 11.3 Decommissioning Procedures......Page 296 11.3.1 Late-Life Operations......Page 297 11.3.4 Mothballed Facilities And Equipment......Page 298 11.4.1 Deconstruction......Page 299 11.4.2 Demolition......Page 300 11.5.1 Contractor Management......Page 301 11.5.2 Safety Culture......Page 302 11.5.5 Hazard Evaluation......Page 303 11.5.6 Safe Work Practices......Page 304 11.5.7 EHS and Process Safety Procedures......Page 305 11.5.8 Training and Competence Assurance......Page 306 11.5.11 Operational Readiness Review......Page 307 11.5.12 Emergency Management......Page 308 11.5.14 Auditing......Page 309 11.5.16 Remediation......Page 310 11.6.3 Action Tracking......Page 311 11.6.5 Stage Gate Reviews......Page 312 11.7 Summary......Page 314 12.1 Document Management......Page 315 12.2.1 Front End Loading 1 Stage......Page 318 12.2.2 Front End Loading 2 Stage......Page 319 12.2.3 Front End Loading 3 Stage......Page 320 12.2.4 Detailed Design Stage......Page 321 12.2.5 Construction Stage......Page 323 12.2.6 Commissioning and Startup Stage......Page 326 12.2.7 Handover......Page 327 12.2.8 Operation Stage......Page 328 12.2.9 End of Life Stage......Page 331 12.3 Summary......Page 332 APPENDIX A. TYPICAL PROCESS SAFETY STUDIES OVER PROJECT LIFE CYCLE......Page 333 APPENDIX B. PROJECT PROCESS SAFETY PLAN......Page 335 APPENDIX C. TYPICAL HAZARD & RISK REGISTER......Page 338 APPENDIX D. SAFETY CHECKLIST FOR PROCESS PLANTS......Page 341 APPENDIX E. EXAMPLE OF SITE-SPECIFIC DECOMMISSIONING CHECKLIST/QUESTIONNAIRE......Page 355 APPENDIX F. TYPICAL PROJECT DOCUMENTATION......Page 362 APPENDIX G. STAGE GATE REVIEW PROTOCOL FOR PROCESS SAFETY......Page 377 REFERENCES......Page 405 INDEX......Page 419 EULA......Page 423 There is much industry guidance on implementing engineering projects and a similar amount of guidance on Process Safety Management (PSM). However, there is a gap in transferring the key deliverables from the engineering group to the operations group, where PSM is implemented. This book provides the engineering and process safety deliverables for each project phase along with the impacts to the prohect budget, timeline and the safety and operability of the delivered equipment