Operations: J - How Can We Operate Safely?

J - How Can We Operate Safely?
Operations
Operating Procedures
A good set of operating procedures thoroughly covers:
Startup
Normal Operation
Emergencies
Shutdown
Define the content, scope and level of detail required
for the routine or non- routine sequencing of activities
to ensure safe and efficient operation within designated
operating envelopes.
Formally captures good operating practice.
Key Contents
Plant process description.

Plant operating envelopes.
Plant unit & location
Plant occupational health hazards & risks.
Plant safety hazards & risks.
Plant environmental hazards & risks.
Task description
Basic Steps
Task description.
Task specific assessment of HSE hazards.
Identification of any
safety/environmentally
CRITICAL STEPS.
A Safer
Site
Routine Operating
Instructions
Start-up Operating
Instructions.
Note :- Provision for the

collection of comments
from the users.
Emergency Shutdown Operating

Instructions
Temporary Operating Instructions.
Human Factors in Instructions

Good Practice Format
Clarity & exactness of instruction

e.g Fill at 1 tonne/hr.
Logical flow/sequence of actions.
Simple language & ease of reading
i.e. bullet points & flow diagrams,
use digital images.
Clear CAUTIONS & WARNINGS.
Document control.
Operating Envelopes
Operating Envelopes
Operating Envelopes define the
parameters of normal operation.
When parameters go outside the operating
envelope, one of the following is required:
Continue running and make
adjustments and monitor.
Normal shutdown.
Emergency shutdown.
Design Envelope vs Operating Envelope

Operating Envelope
Design Envelope
Availability
Integrity
Trip Envelope
Reduction in Demand
Alarm Envelope
Optimisation Envelope
Reduction in Demand
Profit
Training
Competency
Training
Qualifications for technical and field personnel.
Emphasizes the rationale for doing things and
seeks a higher level of understanding of process
hazards.
Process simulator very useful and effective.
Competency evaluation in field.
Regular refresher training.
All levels of Staff
Contractors competency verified
Competence Management
Defining of job roles and requirements
Assessment of competence against
requirements
Training program to close competency gaps
Verification of competency, re-verification
Documentation of competency
Key Process Safety Competence

Know the hazards of your work area
Understand how hazards are controlled
Follow the Golden Rules
Know how to contact Technical
Authorities
??????? (Know what you dont know)
Case History - CH1
Hoechst-Celanese - 1987
Case History 1 - Celanese

1987 Hoechst-Celanese in Pampa, Texas
Butane oxidation unit to manufacture acetic acid.
Unit was in startup phase following 24 hour
outage.
Reactor 68 m3 12 metres long; 2.5 metres
diameter was not properly purged with nitrogen
during shutdown.
Startup purge had not begun.
Operator omitted manual purge step
System was pressured to 700 psig (48 barg) at
150oC; hydrocarbon remained in reactor from
shutdown.
The Incident
What Happened
Detonation caused line to open.
Estimated release of 36 tonnes C4
Vapor cloud explosion and fire within 30 seconds.
Utility area was the suspected ignition source.
3 fatalities, 39 injuries
Fire took 12 hours to extinguish
Damage $550 millions
All fatalities were a result of projectiles and debris.
Damage Details
INCINERATOR
TANK
FARM
MEK
TANK FARM
RAIL SIDING
ACRYLATES
BUTYL ACRYLATE
COOLING
TOWERS
WAREHOUSE
BOILER
SPHERES
UTIL
UTIL
TURBINE
BUTANE
OXIDATION
ACETIC
TANK FARM
ANHYDRIDE
100% DESTRUCTION
WAREHOUSE
LAB
ADMIN BLDG
200 M
Damage Details - 2
Radius of 100% destruction 61m (200ft).
All buildings within 122m (400ft) destroyed.
Buildings within 274m (900ft) sustained heavy
damage.
House 0.8km (0.5 mile) from plant severely
damaged.
Pickup truck 4km (2.5 miles) from plant was
physically moved
Firewater system was above ground and was
destroyed as a result of the explosion.
Engineering design did not inhibit procedural
error, building siting added to the problem.
Damage Details Contd
Major Lessons Learned

Operators must be
Tr
a
thoroughly trained in startup ining/
Co
mp
procedures and know not to
et e
nce
deviate from them.
Fire suppression systems
must be protected.
Me
c
ha
ni c
al
I
nt e
gr i
ty
Non Routine Activity
SAFE WORK PRACTICES

System to ensure that hazardous work is
always done safely and consistently.
Working in confined spaces

Gas testing
Blinding/isolations
Safe work permits
Any others?
BP Golden Rules of Safety

Confined Space Entry
Working at Heights
Driving Safety
Permit to Work
Energy Isolation
Ground Disturbance
Lifting Operation
Management of Change
DETAILS

Operations: J - How Can We Operate Safely?

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J - How Can We Operate Safely?

Plant process description.

Note :- Provision for the

Emergency Shutdown Operating

Temporary Operating Instructions.

Human Factors in Instructions

Clarity & exactness of instruction

Design Envelope vs Operating Envelope

Key Process Safety Competence

Case History - CH1

Case History 1 - Celanese

Damage Details Contd

Major Lessons Learned

Non Routine Activity

SAFE WORK PRACTICES

Working in confined spaces

BP Golden Rules of Safety

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