Process, Power and Marine DivisionDesign Safety into Your PlantMary Kay O’Conner Process Safety Symposium

Frank JoopGlobal Business DevelopmentIntergraph Process, Power & Marine

Be Pro-active – “SAFETY FIRST”

Safety is at the Forefront

Was this your plant…………….

The Basics

Risk Reduction– Instrument are a well accepted risk reduction

system– Safety for personnel, facility and environment

Contributors to an accident– Course– Process deviation– What is released to the atmosphere

Risk Reduction

Increasing Risk

Process RiskTolerable RiskResidual Risk

Necessary Risk Reduction

Actual Risk Reduction (ALARP)

ProcessDesignBPCSAlarmsReliefSIS

Tolerable Risk

The Standards

ISA S84.01 and IEC 61508 Framework for the design Key steps are:

– Process design– HAZOP and Risk analysis– Determine protection layers– Define Safety Integrity Level (SIL)– Define SIS– Specification of SIS– Design– Operating procedures– Commissioning– Modification coupled back to the process design

Risk Assessment

What if Checklist What if/ Checklist

HAZOP FMECA FTA

Method Smaller system

For repeatable systems

For proven designs

For larger and more complex systems

For any type or size system

For any type or size system

Plus Fast and simple

Standardized approach

Good and fast method

Very thorough

Very thorough

Very thorough, with diagrams

Minus Not very thorough

No new analysis components

Need experienced personnel

Very time consuming

Very time consuming

More for individuals rather then a group approach which means less input from experience

HAZOP’s – What, Why and How?HAZOP’s – What, Why and How?

The best, most rigorous method for hazard assessment Team of 5 – 8 experienced engineers, operators Usually after the design / change is complete Impacts time TO market and time IN market

Hazard Identification

Likelihood vs. Severity

Risk reduction

Process Safety Information Systems

Design Control

Maintenance Finance

Safety

Process Safety is Mission CriticalProcess Safety is Mission Critical

Law License to operate

Cost Injury, plant damage Abnormal upsets

Image Staff Community Marketplace

HAZOP’s – What, Why and How?HAZOP’s – What, Why and How?

DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION     

HAZOP = Hazard and Operability Studies Study of the possibility of deviation from the design intent HAZOP Fundamentals:

– Deviation– Course

Key words are:– Flow, Temperature, Pressure, Level, Separate (settle, filter, centrifuge),

Composition, React Mix, Reduce (grind, crush, etc.), Absorb, Corrode Erode

Operational words– Isolate, Drain, Vent, Purge, Inspect, Maintain, Start-up, Shutdown

Secondary Key Words– No, Less, More, Reverse, Also, Other, Fluctuation, Early, Late

HAZOP’s – What, Why and How?HAZOP’s – What, Why and How?

DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION  

No, Flow StrainerBlockage

Pump cavitationsWrong mixing

Pressure measurementAt pumpInspection of filter

Add instr.

Verifying each system

Process Design Instrument design Piping layout Material ordering HAZOP

– Found error– Design change ($$)– Change order for material/equipment ($$$$$)

HAZOP’s late in the scheduleHAZOP’s late in the schedule

DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION  

No, Flow StrainerBlockage

Pump cavitationsWrong mixing

Pressure measurementAt pumpInspection of filter

Add instr.

Impact / Follow on Effect:

- DCS Configuration- DCS HMI (Graphics)- Alarm Management- Asset Management- Instrumentation Design- Procurement Changes- Vendor Communications- Piping Changes- Material Changes- Construction Planning- Commissioning- Spare Parts Loading- Documentation- Etc...

Multiple by thousands of potential “Safe-guards”

HAZOP’s late in the scheduleHAZOP’s late in the schedule

HAZOP’s – Earlier in the scheduleHAZOP’s – Earlier in the schedule

Process Design Make HAZOP part of design process early on Instrument design Piping layout Material ordering HAZOP (final)

– No errors– No Design change– No Change order for material/equipment

Reduced design and CAPEX risks

SmartPlant Process Safety enables to design safety into your plant and

reduces the operational risks. Design = EPC Operational = OO

The Solution The Solution

SPPS Process Safety information

Hazop study

Knowledge base

Knowledge from experts, captured once only

Structured database

Full, auditable record

Comprehensive

Consistent

- Up to 50% time & cost reduction

P&IDsLessons learned

Plant safety information today

Hazop study

Maintenance Plant Modification

Operation

Lack of safety data impacts

Plant safety knowledge

The Solution

Equipment Models in SmartPlant Process Safety

Knowledge about the behaviour of process equipment is essential for hazard identification.

Each equipment type in SPPS has a “Model”.– Describes behaviour, failure modes and hazards.– Connects to other equipment through ports.– Models collected into a “Unit Model Library”.

“Instances” of these equipment models are used in the P&IDs which SPPS analyses.

The Solution

Flow Modelling…

Pin Pout

QoutQin

ToutTin

Pout

+

+

Pin

+

+

etc…

+

– ++ –

noQoutnoQin

Consequence:dry running

+

+

+

+

+ ++

+

+

Centrifugal pump:

The Solution

Plant Modelling…

The Solution

Equipment Models

The SolutionFault-consequence Lists…

The SolutionFault-consequence detail

The Solution

Fault-Consequence Assessment

MoC workflow

P&IDs Plant Safety database from SPPS and Hazop study

Existing plant

Proposed modification/new batch sheet

Modify P&IDs

Run SPPS to find

hazards

Engineering approval

Safety approval

Permit to work

Compare and Hazop new cause-consequences

Final approval

The Solution

Comparing before and after Hazops

The Solution

Any more F/C in this Node & deviation?

Brainstorming

HAZOP’s w/ SP Process SafetyHAZOP’s w/ SP Process SafetyTraditional HAZOP Study SP Process Safety HAZOP Study

Manually divide P&ID’s / Plantinto “nodes” to study and mark-upP&ID’s Manually prepare “node” work-sheet Focus on individual node and deviationat a time Manually work to identify fault-Consequence both inside and outside the node Manually identify and document safe-guards / instrumentation Assign actions and manually communicate them to respective disciplines Manually document study for future reference / audits

Automatically create “nodes” using intelligent data / rules from SmartPlant P&ID

Semi-Automatic preparation of “node” worksheet, interactive navigation and selection from P&ID database

Interactive visual aid to P&ID for brain storming activities

Automatic recommendations of Safe-Guards

Electronic and collaborative assignment of actions for respective disciplines

Automatic email-notification of actions, including action management functions

Automatically generate HAZOP reports / results

History management / comparison reports

Process Safety Integration Vision...

CORPORATE SAFETY

MEMORY

Data & Document

Management‘eEngineering

Integration Hub’

TE

FTE

F

TEF

TEF

TEF

SP- PID

SP3D

SPI

SPEL

TE

FT

EFTEF

BROWSER

TEF HAZOPS ACCIDENT DATA

MoC

SECURITY ACCIDENT INVESTIGATION

CALCULATIONS

HUMAN FACTORS

Business Results Achieved

Hazard

Identification

Automation

Risk

Assessment

Action

Management

Data

Handover

Early Hazard

Elimination

50% time & cost reduction Project schedule reduction

Consistent, thorough, Auditable Re-usable, comparable

Action validation

Unified record Faster re-hazops Better MoC Lessons learned

Safety of acquisitions

Build corporatesafety memory

(CSM)

Capture knowledge of experts once and re-use always

Check designsUsing CSM

Better design Make changes before limited, costly Shorter Hazop studies

Better action management

Visual aid to improve brainstorming

Summary

Full, auditable, consistent Hazops record

Reduced time, cost and tedium

Early design checking enables change before becomes costly, limited

Knowledge capture and use

– Company’s experts’ experience

– lessons learned

Hazop study results - living data

– Supporting MoC

– Accessible information

Process, Power and Marine Division

Integrating the Engineering Enterprise…