Guidelines for Process Safety in Outsourced Manufacturing
Description
This book focuses on the outsourced manufacturing process and roles the affected parties assume. It applies the elements of risk based process safety to minimize the potential of process safety events. The book illustrates how the twenty Elements of the CCPS Risk Based Process Safety (RBPS) management approach can be used as the framework for a consistent, structured method to safely execute outsourced manufacturing. Additionally, ten case studies are provided detailing how breakdowns in the transfer of information in the various outsourced manufacturing process steps and failure for affected parties to understand their role in the process have led to process safety incidents.
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The Center for Chemical Process Safety (CCPS) has been the world leader in developing and sharing information on process safety management and technology since 1985. The CCPS, an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has published over one hundred books in its process safety guidelines and process safety concepts series. Also, CCPS has helped develop over thirty training courses in its Safety and Chemical Engineering Education (SAChE) process safety series. Through AIChE, CCPS is involved with the Annual Safety in Ammonia Plants & Related Facilities Symposium. CCPS is supported by the contributions and voluntary participation of more than 250 companies globally.
Content
List of Figures xiii
List of Tables xv
Acronyms and Abbreviations xvii
Glossary xxi
Acknowledgements xxvii
Dedication xxix
How to Use this Book and Accompanying Online Materials xxxi
Foreword xxxiii
Chapter 1 Introduction 1
1.1 Challenges of Managing Process Safety in Outsourced Operations 2
1.2 Historical Context 2
1.3 Types of Outsourced Manufacturing 3
1.4 Scope 4
1.5 Audience 5
1.6 Why Outsource Manufacturing? 5
1.7 Disadvantages and Challenges of Outsourced Manufacturing 6
1.8 Joint and Individual Company Responsibilities in Outsourced Manufacturing 7
1.9 Process Safety Management Systems 8
1.10 Role of Leadership in Process Safety 12
1.11 Format of This Book 15
1.12 References 16
Chapter 2 Overview of the Outsourced Manufacturing Workflow 17
2.1 Introduction 17
2.2 Develop and Validate the Business Case for Outsourcing 19
2.3 Complete Applicable R&D 19
2.4 Perform Initial Screening of CMs and Brokers 20
2.5 Select Broker and CM 20
2.6 Perform Technology Transfer 21
2.7 Perform Final Assessment and Implement Manufacturing Contract 22
2.8 Pre-startup Activities and First Run 23
2.9 Managing Process Safety in Contract Operations 23
2.10 Key Concepts of RBPS in Outsourced Manufacturing 24
2.11 References 25
Chapter 3 Develop and Validate the Business Case for Outsourcing 27
3.1 Introduction 28
3.2 Evaluate the Need to Outsource and Develop the Scope of Work 28
3.3 Determine Scope of Work 31
3.4 Determine Initial Risk Based Process Safety (RBPS) Concerns 32
3.5 Perform Regulatory Checks/Reviews 32
3.6 Develop Expectations for Broker and CM 33
3.7 Summary 33
3.8 References 34
Chapter 4 Special Focus on Research and Development (R&D) 35
4.1 Introduction 35
4.2 Research and Evaluate Process Alternatives 39
4.3 Collection and Development of PSI 41
4.4 Lab-Scale Experimental Studies to Define Conceptual Process Design/Unit Operation Selection 50
4.5 Inherently Safer Design Analysis and Process Selection 52
4.6 Pilot-Scale Studies 54
4.7 Preliminary Technology Package 56
4.8 Process Development and Optimization 57
4.9 Technology Transfer Package 58
4.10 Continuous Improvement 59
4.11 Summary 59
4.12 References 60
Chapter 5 Initial Screening of CMs and Brokers 61
5.1 Introduction 62
5.2 Initial Search for a CM 65
5.3 Self-Evaluations 70
5.4 Screening Technology Package 71
5.5 Summary 72
5.6 References 73
Chapter 6 Broker and CM Evaluation 75
6.1 Introduction 76
6.2 Final Evaluation of Brokers 78
6.3 Final Evaluation of CMs 78
6.4 Broker and CM Evaluation of Client 85
6.5 Evaluating Recommended Changes from RFP Specifications 87
6.6 RBPS Elements to Consider 88
6.7 Performance Review 89
6.8 Going Forward with Selected CM 90
6.9 Summary 90
6.10 References 91
Chapter 7 Information and Technology Transfer 93
7.1 Introduction 93
7.2 Process Description 95
7.3 Hazards 96
7.4 Process Safety Information: Technology and Equipment Hazards 105
7.5 Process Safety Information: Unique Hazards 107
7.6 Process Safety Information & Knowledge Management Evaluation 108
7.7 Conceptual Design HIRA 109
7.8 Process Safety Events 111
7.9 Manufacturing: Steps and Process Flow 111
7.10 Supplemental information 112
7.11 Research and Development: Technology Transfer 112
7.12 Technology Transfer and Verification of Understanding 113
7.13 Summary 113
7.14 References 114
Chapter 8 Assessment and Final Contract 115
8.1 Introduction 115
8.2 Site Visit and Gap Assessment 117
8.3 HIRA, HSE, and Governance Assessment Activities 118
8.4 Final Contract 121
8.5 Summary 122
8.6 References 122
Chapter 9 Pre-Startup Activities and First Run 123
9.1 Introduction 123
9.2 Write or Revise Procedures 125
9.3 Competency Development and Training 134
9.4 Finalizing the HIRA for First Run 135
9.5 Security Assessments 135
9.6 Equipment Pre-commissioning 136
9.7 Pre-startup Safety Review (PSSR) 138
9.8 Joint Project Review 139
9.9 Equipment Commissioning and First Run 140
9.10 Summary 143
9.11 References 144
Chapter 10 Managing Process Safety in Contract Operations 145
10.1 Introduction 146
10.2 Manage Risk 149
10.3 Learn from Experience and Continuous Improvement 156
10.4 Governance 162
10.5 Idling and Decommissioning 163
10.6 Summary 169
10.7 References 169
Chapter 11 Call to Action: Outsourced Manufacturing Without PS Process Safety Accidents 171
11.1 The Opportunity 171
11.2 Conclusion 173
11.3 References 176
Appendix A Analysis of case studies 177
Appendix B Outsourced Manufacturing Project Checklist 181
Appendix C Example Technology Transfer Checklists 183
Appendix D CM Assessment and Self-Evaluation Checklists 201
Appendix E HIRA Scope Checklists for Outsourced Manufacturing 217
E.1 Introduction 217
E.2 HIRA Scope Checklist Overview 217
E.3 HIRA Scope Checklist 220
Appendix F Selected Additional Resources 225
Appendix G An Optimal Outcome for the Optima Belle Case 233
G.1 Background 233
G.2 Developing the Business Case for Outsourcing 234
G.3 Client Self-Evaluation 234
G.4 Perform Initial Screening of Brokers and CMs 236
G.5 Complete Applicable R&D 239
G.6 Select CM 242
G.7 Perform Technology Transfer 243
G.8 Perform Final Assessment and Implement Contract 244
G.9 Pre-startup, Startup, and First Run 246
G.10 Manage Contract Operations 248
G.11 References 250
Index 251