Safety and Security Review for the Process Industries (eBook)

Application of HAZOP, PHA, What-IF and SVA Reviews

Dennis P. Nolan (Autor)

eBook Download: PDF | EPUB

2014 | 4. Auflage
192 Seiten
Elsevier Science (Verlag)
978-0-323-32355-0 (ISBN)

Infos

Dennis Nolan, drawing on decades of experience as a well-known safety author and senior loss prevention specialist at Saudi Aramco, provides the essential procedures and checklists in Safety and Security Review for the Process Industries. In addition to guiding the reader through the selection and execution of efficient and complete hazard analysis and safety reviews (such as HAZOP, PHA, What-If, SVA, LOPA, Bowtie), Nolan shares his personal experience and illustrates procedures with real-world examples. Updated throughout to reflect changing practices, the fourth edition expands its scope to include maintenance, exploratory drilling, and governmental regulation updates. It adds best practice guidelines on CHAZOP reviews, expands on threats in the security vulnerability analysis, and includes more information on chemical process facilities and hydrocarbon/chemical plant safeguards. Up-to-date form templates and 'what-if checklists are also available for purchasers of the book to download, making this a complete safety review toolkit. - Helps you to achieve compliance and avoid disasters: provides the checklists and best-practice guidance needed to negotiate the labyrinth of hazard analysis and safety review procedures - Keeps your knowledge up-to-date: coverage of the latest forms of hazard analysis and safety review, including LOPA and Bowtie - Saves time and money: demonstrates how each of the typically required reviews is related, so that information and conclusions used on one may be transferred or adapted for another

Dr. Dennis P. Nolan has had a long career devoted to risk engineering, fire protection engineering, loss prevention engineering and systems safety engineering. He holds a Doctor of Philosophy degree in Business Administration from Berne University, Master of Science degree in Systems Management from Florida Institute of Technology and a Bachelor of Science Degree in Fire Protection Engineering from the University of Maryland. He is a U.S. registered professional engineer in fire protection engineering in the state of California.He is currently on the Executive Management staff of Saudi Aramco, located in Dhahran, Saudi Arabia, as a Loss Prevention Consultant/Chief Fire Prevention Engineer. He covers some of the largest oil and gas facilities in the world. As part of his career, he has examined oil production, refining, and marketing facilities under severe conditions and in various unique worldwide locations, including Africa, Asia, Europe, the Middle East, Russia, and North and South America. His activity in the aerospace field has included engineering support for the NASA Space Shuttle launch facilities at Kennedy Space Center (and for those undertaken at Vandenburg Air Force Base, California) and 'classified” national defense systems. Dr. Nolan has received numerous safety awards and is a member of the American Society of Safety Engineers, He is the author of many technical papers and professional articles in various international fire safety publications. He has written at least four books, several published by Elsevier.

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Dennis Nolan, drawing on decades of experience as a well-known safety author and senior loss prevention specialist at Saudi Aramco, provides the essential procedures and checklists in Safety and Security Review for the Process Industries. In addition to guiding the reader through the selection and execution of efficient and complete hazard analysis and safety reviews (such as HAZOP, PHA, What-If, SVA, LOPA, Bowtie), Nolan shares his personal experience and illustrates procedures with real-world examples. Updated throughout to reflect changing practices, the fourth edition expands its scope to include maintenance, exploratory drilling, and governmental regulation updates. It adds best practice guidelines on CHAZOP reviews, expands on threats in the security vulnerability analysis, and includes more information on chemical process facilities and hydrocarbon/chemical plant safeguards. Up-to-date form templates and "e;what-if checklists are also available for purchasers of the book to download, making this a complete safety review toolkit. - Helps you to achieve compliance and avoid disasters: provides the checklists and best-practice guidance needed to negotiate the labyrinth of hazard analysis and safety review procedures- Keeps your knowledge up-to-date: coverage of the latest forms of hazard analysis and safety review, including LOPA and Bowtie- Saves time and money: demonstrates how each of the typically required reviews is related, so that information and conclusions used on one may be transferred or adapted for another

Textauszug

Chapter 1

Purpose

This chapter summarizes the US regulations that require Process Hazards Analysis (PHA) and Security Vulnerability Analyses (SVAs). It highlights the most common types of reviews undertaken and the depth of the subject reviews, discussing both qualitative (e.g., PHAs, What-Ifs, and HAZOPs) and quantitative methods (Event Trees, Fault Trees, Failure Mode and Analysis, etc.). It also discusses the need to undertake such reviews for periodic revalidation and facility changes. The benefits of such reviews can be used to demonstrate that the required PHAs or SVAs have been undertaken to interested parties.

Keywords

American Institute of Chemical Engineers (AIChE); American Petroleum Institute (API); Chemical Facility Anti-Terrorism Standard (CFATS); Chemical Safety Hazard Investigation Board (CSB); Department of Homeland Security (DHS); Environmental Protection Agency (EPA); executive order; hazard identification; hazardous substances; methodology; Occupational Safety and Health Administration (OSHA); procedures; Process Safety Management (PSM); regulations; security requirements

This publication is intended to provide guidance to qualitative hazard analyses conducted for industrial and commercial process, specifically for PHA (Preliminary Hazard Analysis), What-If, and HAZOP (Hazard and Operability) review teams. It also highlights how the methodology and procedures used for these reviews can be adopted and applied for Security Vulnerability Analysis (SVA). This book describes the nature, responsibilities, methods, and documentation required in the performance of such reviews. This ensures that these reviews are conducted in a timely, effective, objective, and consistent manner as may be prescribed by a company’s Process Safety Management (PSM) policy and security requirements. This book relies heavily on the common practices in the petroleum, chemical, and petrochemical industries because most of the major hazardous processes are located in these industries and these facilities are increasingly becoming a potential target for security incidents.

The safety and security of process facilities are an important part of a company’s operations. Worldwide petrochemical safety regulations, international security threats, and a company’s own PSM policies require that a hazard identification, process safety, and security analysis review of its existing and proposed operations be accomplished.

The worldwide petroleum and chemical insurance market estimates for the period 1993–2013 that there have been about 1,100 major insurance claims (i.e., major incidents), amounting to approximately $32 billion (for property damage and business interruption). Their analysis estimates that the worldwide risk has been constant over this period, that is, the average frequency and cost impact has been a constant trend, neither decreasing nor increasing. This equates on average to 110 losses totaling $2–3 billion per year. Additionally, these losses would fit a traditional loss incident ratio triangle (see Figure 1.1) with an ever-increasing number of losses as the magnitudes of the losses decrease (i.e., as the steps in the triangle widen).

Figure 1.1 Loss triangle, number versus magnitude.

Today, new projects are in the region of $50+ billion, which equates to the Deepwater Horizon incident loss (April 20, 2010), and the potential for even larger losses from a single incident is still a possibility. The industry must do more to prevent these incidents and improve safety so that this trend decreases.

Most incidents occur during periods of nontypical operations, such as maintenance activities, startup or shutdown, and drilling activities. This is when more attention, knowledge, and experience are required from personnel to safely manage the facility. Therefore, special attention needs to be applied to circumstances that are out of the normal operating mode of processes.

The limits of hazardous substances cited by both the US Occupational Safety and Health Administration (OSHA) and the Environmental Protection Agency (EPA) regulations dictate the application of PSM elements at almost all of a company’s facilities. These reviews are intended to reduce the probability and consequences of a major incident that would have a detrimental impact on employees, the public’s well-being, onsite or offsite properties, the environment, and most importantly to the company itself, its continued business operation and survival. It should also be noted that there may be a general adverse public reaction and therefore a company’s reputation may suffer. Hazard identification and process analysis reviews are not intended to identify the minor “slips, trips, or falls”; these are the responsibility of the company’s general safety requirements and can be analyzed with other tools (for example, Job Safety Analysis (JSA)).

In March 2003, the United States implemented Operation Liberty Shield to increase readiness and security in the United States, primarily due to international threats from nongovernment affiliated, self-motivated political and religious groups. One objective of this operation was to implement comprehensive process security management programs into existing OSHA, EPA, and FDA laws to address deliberate acts of threats of terrorism, sabotage, and vandalism. In April 2007, the Department of Homeland Security (DHS) issued the Chemical Facility Anti-Terrorism Standard (CFATS). DHS uses this document to help identify, evaluate, and ensure effective security at high-risk chemical facilities. Included in this responsibility is the requirement for chemical facilities handling chemicals above a threshold amount to submit an SVA for DHS review and approval along with a Site Security Plan (SSP). A potential fine of $25,000 per day, an inspection and audit by DHS, or an order to cease operations is stated for noncompliance. The type and amount of chemicals handled that require submission of screening review and SVA submittals are listed on the DHS website. Additionally, internal company security procedures, although confidential, would also require that an adequate security review be undertaken to identify and assess such risks. Because the methodology of conducting process security reviews are similar to existing process hazard analysis reviews, they can be adapted to fit within the parameters of existing procedures established for these analyses. Both API and AIChE have also issued their own guidelines to assist companies undertaking process security reviews. A major process safety consultant recently stated that statistics show that the use of outside security experts for protective services consultations has increased by 200% in the last 5 years. This is due to escalating concerns over workplace and domestic violence, privacy and security practices, and terrorist threats. Process security reviews are not intended to identify minor thefts or mishaps; these are the responsibility of the company’s general security requirements and can be examined with other financial auditing tools.

Recent cybersecurity attacks worldwide have emphasized the importance of software security for financial and operational applications within process entities. The National Institute of Standards and Technology (NIST) has recently released a document entitled “Framework for Improving Critical Infrastructure Cybersecurity.” This framework provides a structure that organizations can use to develop and improve cybersecurity programs. NIST was charged with putting the framework together under US Presidential Executive Order 13636 (February 2013), which calls for the development of a voluntary, risk-based cybersecurity framework.

The framework document is described as a living document that will need to be updated to keep pace with changes in technology, threats, and other factors, and to incorporate lessons learned from its use. The document describes three main elements: framework core, tiers, and profiles. The framework core presents five functions: identify, protect, detect, respond, and recover. Together, they allow an organization to understand and shape its cybersecurity program. Tiers describe the degree to which an organization’s cybersecurity program meets goals identified in the framework. Profiles help organizations improve their current cybersecurity programs.

The purpose of the safety and security evaluations described in this book is to identify the major risks facing the industry that have the potential for severe impacts. It identifies simple processes and procedures to apply these reviews in an easy, practical manner.

PHA, What-If, and HAZOP reviews are the most common industry qualitative methods used to conduct process hazard analyses, while SVAs are typically applied for process security analyses. It is qualitatively estimated that up to 80% of a company’s hazard identification and process safety analyses may consist of PHA, What-If, and HAZOP reviews, with the remaining 20% from Checklist, Fault Tree Analysis, Event Tree, Failure Mode and Effects Analysis, and so on. Chapter 5 highlights other reviews that are periodically utilized by the process industries.

An experienced review team can use the analyses described to generate possible deviations from design, construction, modification, and operating intent or from deliberate actions that define potential consequences. These consequences can then be prevented or mitigated by the application of the appropriate safeguards.

The reader is reminded that a PHA, What-If, HAZOP, or an SVA report is a living document for a facility. As changes are made to a...

Produkt-Details

• Erscheint lt. Verlag: 1.9.2014
• Sprache: englisch
• Themenwelt: Naturwissenschaften ► Chemie ► Technische Chemie
• Themenwelt: Technik ► Bauwesen
• Themenwelt: Technik ► Umwelttechnik / Biotechnologie
• Themenwelt: Wirtschaft
• ISBN-10: 0-323-32355-3 / 0323323553
• ISBN-13: 978-0-323-32355-0 / 9780323323550