Guidelines for Integrating Process Safety into Engineering Projects
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Since 1985, the Center for Chemical Process Safety (CCPS) has been the global leader in developing and disseminating information on process safety management and technology. CCPS, an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has published over 100 books in its process safety guidelines and process safety concepts series, and over 100 training modules through its Safety in Chemical Engineering Education (SACHE) series.
Content
List of Figure xvii
List of Tables xviii
Acronyms and Abbreviations xx
Glossary xxviii
Acknowledgments xxxii
Files on the Web xxxiv
Preface xxxvi
1 INTRODUCTION 1
1.1 Background and Scope 2
1.2 Why Integrating Process Safety is Important 3
1.3 What Type of Projects Are Included? 5
1.4 Project Life Cycle 7
1.5 Relationship to Other Programs 10
1.6 Structure of this Document 13
2 PROJECT MANAGEMENT CONCEPTS AND PRINCIPLES 16
2.1 Common Principles and Structure 16
2.1.1 Statement of Requirements 16
2.1.2 Project Scope 17
2.1.3 Basis of Design 17
2.1.4 Project Budget 18
2.1.5 Project Plan 18
2.1.6 Project Life Cycle 19
2.2 Project Management 20
2.3 Project Governance 21
2.4 Types of Project 22
2.4.1 Greenfield Projects 22
2.4.2 Brownfield Projects 22
2.4.3 Retrofit / Expansion Projects 23
2.4.4 Control System Upgrade Projects 24
2.4.5 Demolition Projects 24
2.4.6 Management of Change Projects 24
2.4.7 Mothballing Projects 25
2.4.8 Re-Commissioning Projects 25
2.4.9 Restarting a Project 25
2.4.10 Post-Incident Projects 26
2.5 Project Organization 26
2.5.1 Pre-Project Team 26
2.5.2 Typical Project Team 27
2.5.3 Unit Based Team 28
2.5.4 Equipment Based Team 28
2.5.5 Site Based Team 28
2.5.6 Small Projects 28
2.5.7 Roles and Responsibilities 29
2.6 Strategies for Implementation 32
2.6.1 Contractor Selection 35
2.6.2 Engineering Only 36
2.6.3 Engineering and Procurement 36
2.6.4 Engineering, Procurement and Construction 36
2.6.5 Operation 37
2.6.6 Contractor Oversight 37
2.7 Risk Management 38
2.8 Project Controls 40
2.8.1 Planning and Progress 40
2.8.2 Estimates, Budgets and Cost Control 41
2.8.3 Reporting 41
2.8.4 Metrics 41
2.8.5 Action Tracking 42
2.8.6 Change Management 42
2.9 Other Considerations 43
2.9.1 Materials Management 43
2.9.2 Quality Management 43
2.9.3 Lessons Learned 43
2.9.4 Post-Project Close-Out 44
2.10 Stage Gate Reviews 44
3 FRONT END LOADING 1 46
3.1 Preliminary Hazard Identification 48
3.2 Preliminary Inherently Safer Design Review 49
3.3 Concept Risk Analysis 51
3.4 Other Activities 52
3.4.1 Process Safety and EHS Plan 52
3.4.2 Risk Register 52
3.4.3 Action Tracking 52
3.5 Stage Gate Review 53
3.6 Summary 54
4 FRONT END LOADING 2 56
4.1 Evaluation of Development Options 58
4.1.1 Hazard Identification 59
4.1.2 Preliminary Inherently Safer Design Review 59
4.1.3 Concept Risk Analysis 60
4.1.4 Selection of the Development Option 60
4.2 Further Definition of the Selected Option 63
4.2.1 Design Hazard Management Process 63
4.2.2 Preliminary Inherently Safer Design (ISD) 68
4.2.3 Hazard Identification and Risk Analysis (HIRA) 68
4.2.4 Engineering Design Regulations, Codes, and Standards 69
4.2.5 Design Philosophies/Strategies 70
4.2.6 Preliminary Facility Siting Study 71
4.2.7 Preliminary Fire and Explosion Analysis 72
4.2.8 Transportation Studies 72
4.2.9 Preliminary Blowdown and Depressurization Study 74
4.2.10 Preliminary Fire & Gas Detection Study 74
4.2.11 Preliminary Fire Hazard Analysis 74
4.2.12 Preliminary Firewater Analysis 75
4.2.13 Preliminary Security Vulnerability Analysis 75
4.2.14 Other Engineering Design Considerations 75
4.3 Other Activities 76
4.3.1 EHS and Process Safety Plan 76
4.3.2 Risk Register 76
4.3.3 Action Tracking 76
4.3.4 HIRA Strategy 76
4.3.5 Docum entation 77
4.3.6 Stage Gate Review 77
4.4 Summary 79
5 FRONT END LOADING 3 80
5.1 Evaluation of Development Options 82
5.2 Further Definition of the Selected Option 82
5.2.1 Design Hazard Management Process 84
5.2.2 Inherently Safer Design Optimization 85
5.2.3 Facility Siting and Layout 86
5.2.4 Refine Design Safety Measures 93
5.2.5 Set Performance Standards 94
5.2.6 Hazard Identification and Risk Analysis (HIRA) 95
5.2.7 Safety Assessments 102
5.2.8 Re-Evaluate Major Accident Risk 113
5.2.9 Finalize Important Safety Decisions 113
5.2.10 Finalize Basis of Design 113
5.3 Other Engineering Considerations 114
5.3.1 Asset Integrity Management 114
5.3.2 Quality Management 115
5.3.3 Contractor Selection 115
5.3.4 Brownfield Developments 116
5.4 Other Activities 116
5.4.1 EHS and Process Safety Plans 116
5.4.2 Risk Register 116
5.4.3 Action Tracking 116
5.4.4 Change Management 116
5.4.5 Documentation 117
5.4.6 Preparation for Project Execution 117
5.5 Case for Safety 119
5.6 Stage Gate Review 119
5.7 Summary 120
6 DETAILED DESIGN STAGE 121
6.1 Detailed Design 124
6.1.1 Design Hazard Management Process 124
6.1.2 Inherently Safer Design Optimization 125
6.1.3 Site Layout 126
6.1.4 Design Safety Measures 126
6.1.5 Set Performance Standards 127
6.1.6 Hazard Identification and Risk Analysis (HIRA) 127
6.1.7 Safety Assessments 128
6.1.8 Re-Evaluate Major Accident Risk 129
6.1.9 Other Design Reviews 129
6.2 Procurement 130
6.3 Asset Integrity Management 131
6.4 Other Process Safety Activities 132
6.4.1 Case For Safety 132
6.5 Other Project Activities 133
6.5.1 EHS and Process Safety Plans 133
6.5.2 Risk Register 134
6.5.3 Action Tracking 134
6.5.4 Change Management 134
6.5.5 Documentation 135
6.5.6 Constructability 136
6.5.7 Contractor Selection 137
6.6 Preparation for Construction 138
6.7 Preparation for Pre-Commissioning, Commissioning, and Startup 139
6.8 Stage Gate Review 140
6.9 Summary 141
7 CONSTRUCTION 143
7.1 Planning 146
7.2 Pre-Mobilization 147
7.3 Mobilization 149
7.4 Execution 150
7.4.1 Procurement 151
7.4.2 Fabrication 151
7.4.3 Safety Culture 151
7.4.4 Workforce Involvement 152
7.4.5 Stakeholder Outreach 152
7.4.6 Contractor Management 152
7.4.7 Transportation 153
7.4.8 Equipment and Materials Handling 153
7.4.9 Hazard Evaluation 154
7.4.10 Engineering Design 156
7.4.11 Safe Work Practices 157
7.4.12 Operating, EHS and Process Safety Procedures 159
7.4.13 Training and Competence Assurance 159
7.4.14 Asset Integrity Management 160
7.4.15 Change Management 161
7.4.16 Emergency Response 162
7.4.17 Incident Investigation 163
7.4.18 Auditing 164
7.4.19 Performance Measurement 164
7.4.20 Operations Case for Safety 165
7.4.21 Pre-Commissioning 166
7.4.22 Mechanical Completion 170
7.4.23 Documentation 171
7.5 Other Project Activities 172
7.5.1 EHS and Process Safety Plans 172
7.5.2 Risk Register 172
7.5.3 Action Tracking 172
7.5.4 General Construction Management 172
7.6 De-Mobilization 173
7.7 Preparation for Commissioning and Startup 174
7.8 Final Evaluation and Close-out 175
7.9 Stage Gate Review 175
7.10 Summary 177
8 QUALITY MANAGEMENT 178
8.1 Design/Engineering 183
8.2 Procurement 186
8.3 Fabrication 187
8.4 Receipt 189
8.5 Storage and Retrieval 190
8.6 Construction and Installation 191
8.7 Operation 193
8.8 Documentation 194
8.9 Summary 194
9 COMMISSIONING AND STARTUP 196
9.1 Preparation 199
9.1.1 Planning 199
9.1.2 Safety 201
9.2 Operational Readiness 202
9.2.1 Pre-Startup Stage Gate Review 203
9.2.2 Operational Readiness Review 204
9.2.3 Start-Up Efficiency Review 207
9.3 Commissioning 208
9.3.1 Equipment Testing 209
9.3.2 Commissioning Procedures 211
9.4 Startup 213
9.4.1 Preparation for Startup 213
9.4.2 Calibration of Instruments and Analyzers 213
9.4.3 Startup with Process Chemicals/Fluids 214
9.5 Common Process Safety Elements 215
9.5.1 Hazard Evaluation 215
9.5.2 Safe Work Practices 216
9.5.3 Procedures 217
9.5.4 Training and Competence Assurance 217
9.5.5 Management of Change 218
9.5.6 Incident Investigation 219
9.5.7 Emergency Response 220
9.5.8 Auditing 221
9.5.9 Documentation 221
9.5.10 Performance Measurement 222
9.6 Other Project Activities 222
9.6.1 EHS and Process Safety Plans 222
9.6.2 Risk Register 223
9.6.3 Action Tracking 223
9.7 Performance Test Runs 223
9.8 Handover 224
9.9 Preparation for Ongoing Operation 225
9.10 Project Close-Out 226
9.10.1 Close Out Report 226
9.10.2 Post-Project Evaluation 226
9.11 Summary 227
10 OPERATION 228
10.1 Process Safety Management System 231
10.1.1 Process Safety Culture 233
10.1.2 Compliance with Standards 233
10.1.3 Process Safety Competency 233
10.1.4 Workforce Involvement 234
10.1.5 Stakeholder Outreach 234
10.1.6 Process Knowledge Management 234
10.1.7 Hazard Identification and Risk Analysis 234
10.1.8 Operating Procedures 235
10.1.9 Safe Work Practices 235
10.1.10 Asset Integrity and Reliability 236
10.1.11 Contractor Management 238
10.1.12 Training and Performance Assurance 239
10.1.13 Management of Change 239
10.1.14 Operational Readiness 239
10.1.15 Conduct of Operations 240
10.1.16 Emergency Management 240
10.1.17 Incident Investigation 240
10.1.18 Measurement and Metrics 241
10.1.19 Auditing 242
10.1.20 Management Review and Continuous Improvement 242
10.1.21 EHS and Process Safety Procedures 243
10.2 Other Project Activities 243
10.2.1 EHS and Process Safety Plans 243
10.2.2 Risk Register 243
10.2.3 Action Tracking 243
10.3 Technical Support 243
10.4 Performance Test Runs 244
10.5 Operation Stage Gate Rview 244
10.6 Post-Operational Review 245
10.7 Project Close-Out 246
10.8 Summary 246
11 END OF LIFE 247
11.1 Design for Decommissioning 249
11.2 Planning for Decommissioning 250
11.2.1 Engineering Survey 251
11.2.2 Hazard Evaluation 254
11.2.3 Hazardous Materials 254
11.2.4 Process Safety Plan 255
11.2.5 Utilities 255
11.2.6 Re-Engineering 256
11.3 Decommissioning Procedures 256
11.3.1 Late-Life Operations 257
11.3.2 Cessation of Production 258
11.3.3 Cleaning and Decontamination 258
11.3.4 Mothballed Facilities And Equipment 258
11.4 Deconstruction and Demolition 259
11.4.1 Deconstruction 259
11.4.2 Demolition 260
11.5 Process Safety for Decommissioning 261
11.5.1 Contractor Management 261
11.5.2 Safety Culture 262
11.5.3 Workforce Involvement 263
11.5.4 Stakeholder Outreach 263
11.5.5 Hazard Evaluation 263
11.5.6 Safe Work Practices 264
11.5.7 EHS and Process Safety Procedures 265
11.5.8 Training and Competence Assurance 266
11.5.9 Asset Integrity Management 267
11.5.10 Change Management 267
11.5.11 Operational Readiness Review 267
11.5.12 Emergency Management 268
11.5.13 Incident Investigation 269
11.5.14 Auditing 269
11.5.15 Disposal 270
11.5.16 Remediation 270
11.6 Other Project Activities 271
11.6.1 EHS and Process Safety Plans 271
11.6.2 Risk Register 271
11.6.3 Action Tracking 271
11.6.4 General Decommissioning Management 272
11.6.5 Stage Gate Reviews 272
11.7 Summary 274
12 DOCUMENTATION 275
12.1 Document Management 275
12.2 Process Knowledge Management 278
12.2.1 Front End Loading 1 Stage 278
12.2.2 Front End Loading 2 Stage 279
12.2.3 Front End Loading 3 Stage 280
12.2.4 Detailed Design Stage 281
12.2.5 Construction Stage 283
12.2.6 Commissioning and Startup Stage 286
12.2.7 Handover 287
12.2.8 Operation Stage 288
12.2.9 End of Life Stage 291
12.3 Summary 292
APPENDIX A. TYPICAL PROCESS SAFETY STUDIES OVER PROJECT LIFE CYCLE 293
APPENDIX B. PROJECT PROCESS SAFETY PLAN 295
APPENDIX C. TYPICAL HAZARD & RISK REGISTER 298
APPENDIX D. SAFETY CHECKLIST FOR PROCESS PLANTS 301
APPENDIX E. EXAMPLE OF SITE-SPECIFIC DECOMMISSIONING CHECKLIST / QUESTIONNAIRE 315
APPENDIX F. TYPICAL PROJECT DOCUMENTATION 322
APPENDIX G. STAGE GATE REVIEW PROTOCOL FOR PROCESS SAFETY 337
REFERENCES 365
INDEX 379
ACRONYMS AND ABBREVIATIONS
- ACC
- American Chemistry Council
- AIA
- American Insurance Association
- AIChE
- American Institute of Chemical Engineers
- AIHA
- American Industrial Hygiene Association
- AIM
- Asset Integrity Management
- ALARP
- As Low As Reasonably Practicable
- ANSI
- American National Standards Institute
- API
- American Petroleum Institute
- APM
- Association of Project Management
- ASME
- American Society of Mechanical Engineers
- ASSE
- American Society of Safety Engineers
- AST
- Aboveground Storage Tank
- ATEX
- Appareils destinés à être utilisés en ATmosphères
- Explosibles (94/9/EC Directive)
- BDL
- Building Damage Level
- BEP
- Basic Engineering Package
- BM&M
- Benchmarking and Metrics program
- BOD
- Basis of Design
- BPCS
- Basic Process Control System
- BSI
- British Standards Institution
- BST
- Baker-Strehlow-Tang blast model
- CAD
- Computer-Aided Design
- CAPEX
- Capital Expenditure
- CCPS
- Center for Chemical Process Safety
- CFR
- United States Code of Federal Regulations
- CII
- Construction Industry Institute
- CMMS
- Computerized Maintenance Management System
- CO/CO2
- Carbon Monoxide/Carbon Dioxide
- COMAH
- Control of Major Accident Hazards
- CPT
- Client Project Team
- CRA
- Concept Risk Analysis
- CSB
- United States Chemical Safety Board
- DCN
- Design Change Notice
- DCS
- Distributed Control System
- DHA
- Dust Hazards Analysis
- DHM
- Design Hazard Management
- DHS
- United States Department of Homeland Security
- DIN
- Deutsches Institut fr Normung (German standard)
- DOT
- United States Department of Transportation
- DSP
- Decision Support Package
- EER
- Evacuation, Escape, and Rescue study
- EHS
- Environment Health & Safety
- EI
- Energy Institute
- EN
- European Norm standard maintained by CEN (European Committee for Standardization)
- EPA
- United States Environmental Protection Agency
- EPC
- Engineering, Procurement and Construction
- EPCM
- Engineering, Procurement, Construction and Management
- ERPG
- Emergency Response Planning Guidelines (AIHA)
- ESD
- Emergency Shutdown
- ESDS
- Emergency Shutdown System
- ESDV
- Emergency Shutdown Valve
- EU
- European Union
- F&G
- Fire and Gas
- FAT
- Factory Acceptance Test
- FEED
- Front End Engineering Design
- FHA
- Fire Hazard Analysis
- FID
- Final Investment Decision
- FEL
- Front End Loading
- FMEA
- Failure Modes and Effects Analysis
- FSA
- Functional Safety Assessment
- FSS
- Facility Siting Study
- GB
- Chinese national standard
- GTR
- Guarantee Test Run
- HAC
- Hazardous Area Classification
- HAZID
- Hazard Identification Study
- HAZOP
- Hazard and Operability Study
- HCA
- High Consequence Area
- HIPS
- High Integrity Protection System
- HIPPS
- High Integrity Pressure Protection System
- HIRA
- Hazard Identification & Risk Analysis
- HF
- Hydrofluoric Acid
- HP
- High Pressure
- HFA
- Human Factors Analysis
- HMI
- Human-Machine Interface
- HR
- Human Resources
- HSE
- United Kingdom Health and Safety Executive
- HVAC
- Heating, Ventilation and Air Conditioning
- I/O
- Input/Output
- ICC
- International Code Council
- IChemE
- Institution of Chemical Engineers
- IEC
- International Electrotechnical Commission
- IOGP
- International Association of Oil and Gas Producers
- IPL
- Independent Protection Layer
- IRI
- Industrial Risk Insurers
- ISA
- International Society of Automation
- ISD
- Inherently Safer Design
- ISO
- International Organization for Standardization
- ITP
- Inspection and Test Plan
- ITPM
- Inspection, Testing, and Preventive Maintenance
- JHA
- Job Hazard Analysis
- JIT
- Just-in-Time
- JSA
- Job Safety Analysis
- JV
- Joint Venture
- KPI
- Key Performance Indicator
- LHG
- Liquefied Hazardous Gas
- LNG
- Liquefied Natural Gas
- LOC
- Loss of Containment
- LOPA
- Layer of Protection Analysis
- LOTO
- Lock Out / Tag Out
- LP
- Low Pressure
- LPG
- Liquefied Petroleum Gas
- MAH
- Major Accident Hazard
- MAWP
- Maximum Allowable Working Pressure
- MEL
- Master Equipment List
- MOC
- Management of Change
- MODU
- Mobile Offshore Drilling Unit
- MTI
- Materials Technology Institute
- N2
- Nitrogen
- NACE
- National Association of Corrosion Engineers
- NDT
- Non-Destructive Testing
- NFPA
- National Fire Protection Agency
- NGO
- Non-Governmental Organization
- NIST
- National Institute of Standards & Technology
- NORM
- Naturally Occurring Radioactive Material
- NOx
- Mono-nitrogen oxides: NO and NO2 (nitric oxide and nitrogen dioxide)
- OEM
- Original Equipment Manufacturer
- OM
- Operations Manager
- OPEX
- Operating Expenditure
- ORR
- Operational Readiness Review
- OSHA
- United States Occupational Safety and Health Administration
- P&ID
- Process and Instrumentation Drawing/Diagram
- PCB
- Polychlorinated Biphenyl
- PED
- Pressure Equipment Directive
- PEP
- Project Execution Plan
- PERT
- Program Evaluation Review Technique
- PFD
- Process Flow Diagram
- PLC
- Programmable Logic Controller
- PM
- Project Manager and Preventive Maintenance
- PMBOK
- Project Management Body of Knowledge
- PMI
- Positive Material Identification and Project Management Institute
- PMT
- Project Management Team
- PPA
- Post-project Appraisal
- PPE
- Personal Protective Equipment
- PQP
- Project Quality Plan
- PRA
- Project Risk Assessment
- PS
- Process Safety
- PSI
- Process Safety Information
- PSM
- Process Safety Management
- PSSR
- Pre-startup Safety Review
- PSV
- Pressure Safety Valve
- PreHA
- Preliminary Hazard Analysis
- QA
- Quality Assurance
- QC
- Quality Control
- QM
- Quality Management
- QMS
- Quality Management System
- QRA
- Quantitative Risk Analysis
- RACI
- Responsible, Accountable, Consulted, Informed
- matrix/chart
- RAGAGEP
- Recognized and Generally Accepted Good Engineering
- Practices
- RAM
- Reliability, Availability, and Maintainability study
- RBI
- Risk Based Inspection program
- RBPS
- Risk Based Process Safety
- RCM
- Reliability Centered Maintenance
- RFC
- Ready for Commissioning
- RFI
- Request for Information
- RMP
- Risk Management Program
- ROV
- Remotely Operated Vehicle
- RP
- Recommended Practice (i.e., API guidance)
- RV
- Relief Valve
- SAR
- Search and Rescue
- SAT
- Site Acceptance Test
- SCADA
- Supervisory Control And Data Acquisition
- SCAI
- Safety Controls, Alarms, and Interlocks
- SCBA
- Self-Contained Breathing Apparatus
- SCE
- Safety Critical Equipment/Element
- SDS
- Safety Data Sheet (formerly MSDS)
- SGIA
- Smoke and Gas Ingress Analysis
- SIF
- Safety Instrumented Function
- SIL
- Safety Integrity Level
- SIMOPS
- Simultaneous Operations
- SIP
- Shelter in Place
- SIS
- Safety Instrumented System
- SME
- Subject Matter Expert
- SOR
- Statement of Requirements
- SOW
- Statement of Work
- SOx
- Sulfur oxides: sulfur monoxide (SO), sulfur dioxide
- (SO2), sulfur trioxide (SO3), disulfur monoxide
- (S2O), disulfur dioxide (S2O2), etc.
- SRS
- Safety Requirements Specification
- SUE
- Start-up Efficiency review
- SVA
- Security Vulnerability Analysis
- THA
- Task Hazard Analysis
- TQM
- Total Quality Management
- TR
- Temporary Refuge
- UFD
- Utility Flow Diagram...
