Drc_sp_drc 11-35 Ps Guide Important for Safety Items_eng

8/13/2019 Drc_sp_drc 11-35 Ps Guide Important for Safety Items_eng

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RHODIA PROCESS SAFETY GUIDE DRC 11/35

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Fun!ion "I#PORTA$T FOR SAFETY" ITE#S Pa%e 1/3&

(distribution page)

Re' er e n e ( o u ) e n ! s :

SIMSER+ Elements 2 and 4

*ri!! en b+ For appro, a l

Zno Pasquini Mi!el "riollier #u$ Migault

R!odite! R!odite! R!odia Sa%et$ &iretor

Signature: Signature: Signat ure:

Di s!ri bu! i on o ' (ou) e n!

Reipi e n ! s o' (ra'! Reipi e n ! s o' appro, e ( ,ersi on

For appro , a l For on s ul ! a ! i o n For applia ! i o n For in'or)a ! i o n


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,istor$ o% modi%iations

Pages 6ersion6ersion &ate*omments

7 to ;9 7 7= /o5ember

2992

#uide &R* 79;< reated

;9 2 78 'anuar$2994

Renumber ed as &R* 77; reser5ed %or Sa%et$

Instrumente d S$stems) replaed b$ RR* (Ris?

Redution *lass) 3


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Con!en!s

Pa%e

1. I$TRODUCTIO$..........................................................................................................................................................

-. DEFI$ITIO$ OF A$ IFS ITE#.................................................................................................................................

3. DETER#I$I$G IFS ITE#S.......................................................................................................................................5

;373 #E/ER11PPR.1*,3333333333333333333333333333333333333333333333333333333333333333333333333333333333333333 333333333333333 3333333333333333 333333333333333 3333 equipment>proedures> sa%et$ instrutions and sta%% aut!orisations apable o% restriting parameter de5iations orompensating %or %ailures !i!> i% le%t un!e?ed> ould lead to a maGor aident (see appendi 7)3 "!is guide

intends to de%ine t!e optimum le5el o% I0S items needed to ensure t!e operational sa%et$ o% a %ailit$3

Priniple

"!e list o% important %or sa%et$ items (I0S items) is dran up aording to t!e %olloing priniple:

ist maGor ris? senarios ta?en %rom t!e regulator$ sa%et$ studies onduted in order to obtain t!e %ailit$Hsoperating permit3

ist senarios o% se5erit$ * and , deemed partiularl$ important> identi%ied during t!e ris? anal$ses o% t!e

%ailit$3 ist all pre5enti5e and proteti5e sa%eguards in5ol5ed in all t!e abo5e senarios> Selet !i! o% t!ese sa%eguards are onsidered to be I0S3 *!e? t!at t!ese sa%eguards are su%%iient to ompl$ it! spei%i regulations appliable to t!e %ailit$

onerning maGor aident senarios3 &etermine t!e assoiated I0S items3 .rganise t!e management o% I0S items3

A!ions


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"!ere must be at least one I0S sa%eguard %or ea! o% t!ese senarios and %or ea! spei%i regulator$stipulation3

1ll t!e items in5ol5ed in setting up and maintaining t!e reliabilit$ o% an I0S sa%eguard (as determined in t!eris? anal$ses) o5er time ma$ be spei%ied as important %or sa%et$ items (I0S items) %or t!e sa%eguardonsidered33

"!e I0S items in t!e %ailit$ omprise assigned I0S items and all I0S sa%eguards3 &etermining t!e I0Ssa%eguards onsequentl$ de%ines all I0S items in t!e %ailit$> !i! ma$ be:

1 parameter (measured 5alue to be monitored b$ operators)3 1n item o% equipment (part o% an ati5e or passi5e sa%eguard su! as a sensor> t!res!old detetor> logi>

alarm> atuator> 5al5e> retention d$?e (bund)> antiseismi support> et3)3 0or instrumented sa%et$interlo?s at least t!e sensor and t!e atuator are onsidered as I0S items3

1 proedure (design> maintenane or test rules> operating instrutions> et3)3 1 sa%et$ instrution (!e? and omplete automati ations> ati5ate a %ire etinguis!ing netor?> alert>

e5auation> et3)3 1ppro5al o% personnel %or design> operation and maintenane o% I0S items3

1n item is t!us spei%ied as I0S i% it is seleted b$ t!e %ailit$ manager (see setion 837) as proposed b$ t!eor?ing group !i! onduted ris? anal$ses and regulator$ sa%et$ studies as %orming t!e sa%eguardintended to limit t!e de5iation o% a parameter or ompensate %or a %ailure> !i! i% not ontrolled ould lead toa maGor aident as de%ined in proedure &R* 9


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3.-. IFS ITE#SRESUTI$GFRO#REGUATORYSTUDIESA$DRIS:A$AYSES

3.-.1. Sele!in% senarios an( orrespon(in% sa'e%uar(s

1mong t!e 5arious aident senarios identi%ied during t!e regulator$ sa%et$ studies and ris? anal$ses %or t!e%ailit$> t!ose !i! an ontribute to determining I0S sa%eguards must be identi%ied3

"!e or?ing group s!ould selet all maGor ris? senarios resulting %rom regulator$ sa%et$ studies3 "!e %ilesubmitted to t!e aut!orities is used to list all t!e pre5enti5e and proteti5e sa%eguards in5ol5ed in ea!senario3 "!e supporting table gi5en in appendi 2 ma$ be used3

"!e or?ing group s!ould selet all senarios it! se5erit$ * %rom t!e ris? anal$ses %or t!e %ailit$ toget!erit! senarios it! se5erit$ , deemed partiularl$ signi%iant (see setion 2)3 In most ases t!e !ig! se5erit$means t!at a ris? assessment s!eet !as been dran up %or t!ese senarios> and s!ould generall$ be used to listall t!e pre5enti5e and proteti5e sa%eguards in5ol5ed in ea! senario3 "!e supporting table gi5en in appendi; ma$ be used3

3.-.-. De!er)inin% IFS sa'e%uar(s 'or !


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In t!e eample in appendi items printed in italis are assumed to be based on proedures (design>implementation> aeptane tests> initial testing> inspetion> et3) sta%% aut!orisations (design o%%ie>implementation> instrumentation> inspetion> et3) applied and managed at site le5el3I% t!is is not t!e ase t!e items ma$ be inluded in t!e I0S items %or t!e %ailit$3"!e I0S items seleted are t!ose printed in bold t$pe in t!e table in appendi


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5. DESIG$ A$D I#PE#E$TATIO$ PRI$CIPES

5.1. SAFEGUARDSI$GE$ERA

Sa%eguards must !a5e pro5en reliabilit$3 "!e onept o% pro5en reliabilit$ is based on eperiene aquired inindustr$ %or t!e sa%eguards used in t!e %ailit$ it! similar produts and in similar en5ironments3

Sa%eguard te!nologies are seleted based on eperiene o% eperts su! as design o%%ie sta%%> me!anis orinstrumentation speialists3 "!e seleted equipment must be erti%ied to international standards (IE* 87&I/ 67=2 et3) and its integrit$ appro5ed b$ eternal organisations3

"!e met!ods used to design sa%eguards must also be appro5ed and orrespond to international standards3"!ese met!ods ma$ relate to siJing> alulation> s$stem design> programming o% sa%et$ P*s> et3

5.-. SPECIACASEOFI$STRU#E$TED SAFETYI$TEROC:S

Instrumented sa%et$ interlo?s are speial sa%eguards %or !i! additional design and implementationonstraints appl$3

C


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It is reommended t!at t!e 5arious items %orming instrumented sa%et$ interlo?s are poered %rom an @PS!i! an maintain t!e 5oltage %or 7< to ;9 minutes s!ould an eletriit$ %ailure our3

. #A$AGI$G IFS ITE#S

.1. R ESPO$SI@IITIES

0or a proGet> I0S items %or t!e %ailit$ are determined and onstraints relating to design> implementation>reei5er and initial 5eri%iations !e?ed under t!e responsibilit$ o% t!e proGet leader b$ agreement it! t!e!ost siteHs proess sa%et$ orrespondent3 1%ter startup> I0S items inluding in partiular ompliane it! ot!eronstraints (regular tests> sa%et$ instrutions> training> et3) are managed under t!e responsibilit$ o% t!e %ailit$manager3

0or an eisting %ailit$> t!e site proess sa%et$ orrespondent is responsible %or t!e initial de%inition o% I0Sitems and %or updating t!em during %i5e$earl$ ris? anal$sis re5ies3 "!e %ailit$ manager is responsible %or%ollo up o% I0S items> espeiall$ ompliane it! assoiated onstraints3

.-. ACCEPTA$CETESTSFORIFS E;UIP#E$T

"!e o5erall obGeti5e o% aeptane tests %or I0S equipment is to !e? t!e initial reliabilit$ o% I0S sa%eguards(RR*) required b$ ris? anal$ses3 1ordingl$> aeptane tests %or I0S equipment must be onduted in lineit! a prede%ined plan in order to:

*!e? t!at t!e equipment installed omplies it! t!e de%ined requirements3

*! ? t! lib ti % I0S i t


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tours onduted b$ operating personnel> oupled it! s!eduled inspetions3 "!e results o% t!e 5eri%iationsand inspetions must be noted in a signed and dated ar!i5e doument3

.. R EGUARTESTSOFIFS E;UIP#E$T

"!e o5erall obGeti5e o% regularl$ testing I0S equipment is to maintain t!e reliabilit$ (RR*) o% I0S sa%eguardsspei%ied b$ ris? anal$ses3 Regular tests o% I0S equipment must t!ere%ore be onduted in aordane it! a

prede%ined plan in order to:

*!e? t!e alibration o% I0S equipment3 "est ea! sa%et$ %untion assoiated it! an I0S parameter and spei%ied b$ t!e sa%et$ studies3

"!e inter5al beteen I0S equipment tests ma$ be de%ined b$ a reliabilit$ stud$> ot!erise tests s!ould beonduted at least one a $ear3

"!ese regular tests must be per%ormed b$ t!e appropriate onsite speialists (instrumentation te!niians>me!anial %itters> inspetors> et3) in aordane it! a -Regular test proedure- orresponding to t!e t$pe o%

sa%eguard to be !e?ed (onstrution> instrumented sa%et$ interlo?> pressure relie% 5al5e> et3)3

In partiular t!e proedure must spei%$ t!e t$pe and %requen$ o% testing orresponding to t!e requiredreliabilit$ o% all I0S equipment3 It must also require results to be noted in a signed and dated ar!i5edoument3 "!is proedure must ompl$ it! loal regulations and R!odia "e!nologial Requirements %or,SE (R"R,SE)30or ertain spei%i t$pes o% sa%et$ me!anism !i! are ompletel$ subontrated (eplosion suppressors>sa%et$ interlo?s on rotating ma!iner$> et3) t!e supplier or an eternal speialist ma$ be ontated3

1 ! t t b d i% t! i i i%i t di%% b t t d d t l lt


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Fun!ion "I#PORTA$T FOR SAFETY" ITE#S Pa%e 1-/3&

"!e siteHs -Sa%eguard management proedure-> intended to ontrol all or? and ensure t!at sa%et$ me!anismsare ala$s operated sa%el$> must be %olloed !en ma?ing an$ modi%iations3 0or eample> %or instrumentedsa%et$ interlo?s it de%ines t!e onditions in !i! a t!res!old an be !anged or a sa%et$ interlo? temporaril$disabled (reason> person responsible> aut!orised sta%%> duration> et3)3

"!e proedure must stipulate t!at modi%iations must onl$ be made i% a !ange aut!orisation is granted%olloing a ris? anal$sis3 "!is also results in all douments onerned b$ t!e modi%iation> in partiular t!e listo% I0S items> being updated3

.4. #A$AGI$GDOCU#E$TSREATI$GTOIFS SAFEGUARDSA$DIFS ITE#S

"!e summar$ report setting out I0S items determined is inluded in t!e "e!nial Sa%et$ 0ile %or t!e %ailit$(see &R* 77;7)3

I0S sa%eguards are mar?ed in douments relating to sa%eguards (list o% alarms and sa%et$ me!anisms> sa%et$interlo? matri> list o% pressure release de5ies) also inluded in t!e "e!nial Sa%et$ 0ile %or t!e %ailit$3

"!e list o% all I0S items in t!e %ailit$ must be inluded in t!e operating manual used b$ operations sta%% andmust also be displa$ed ontinuousl$ in t!e ontrol room3I0S equipment are labelled loall$> listing an$ appliable restritions (e3g3 -b$pass pro!ibited-)3

"!e list o% all I0S items %or t!e %ailit$ ma$ be inluded in t!e operating permit appliation submitted to t!eaut!orities3


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APPE$DI 1 6 De'ini!ion o' IFS an( )aor ai(en!s

"!e onept o% Important 0or Sa%et$ entered European la in t!e soalled Se5eso II direti5e on t!e ontrolo% maGoraident !aJards (&ireti5e =82E*)3 "!is !as been transposed into 0ren! la as a ministerialorder and ministerial irular dated 79 Ma$ 2999 on t!e pre5ention o% maGor aidents in5ol5ing dangeroussubstanes and preparations in %ailities lassi%ied %or en5ironmental protetion and subGet to operating

permits3

"ranslated etrat %rom t!e Se5eso II direti5e

-Major accident s!all mean an ourrene su! as a maGor emission> %ire> or eplosion resulting %rom

unontrolled de5elopments in t!e ourse o% t!e operation o% an$ establis!ment o5ered b$ t!is &ireti5e> andlea(in% !o serious (an%er !o


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Fun! ion "I#PORTA$T FOR SAFETY" ITE#S Pa%e 1/3&

APPE$DI - 6 is! o' senarios an( sa'e%uar(s resul!in% 'ro) re%ula!or+ sa'e!+ s!u(ies 8RSS9

RSS

senario$o. CAUSES

DESCRIPTIO$OFSCE$ARIO

Causes Un?an!e( e,en! E''e!s Conse=uenes pS In(epen(en!pre,en!i,e or pro!e!i,e sa'e%uar(s RRCRSS 1 73 Rupture o% &/ 9 liquid p!ase line on

ammonia storage tan? L due to 5ibrationsand me!anial stresses3

Rup!ure o' !


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SCE$ARIORSS$o.

CAUSESDESCRIPTIO$OFSCE$ARIO

Causes Un?an!e( e,en! E''e!s

Conse=uenespS In(epen(en!

pre,en!i,e or pro!e!i,e sa'e%uar(sRRC

RSS 3 73 Rupture o% ammonia storage tan? L

%olloing an eart!qua?e3

In t!e e5ent o% an eart!qua?e> rup!ure o' a))onia

s!ora%e !an leads to ammonia gas and aerosol beingreleased into t!e atmosp!ere LEstimated number o% deat!s 79 (se5erit$ N *)

C Pre5enti5e

1ntiseismi onstrution ensuring integrit$ o% t!e %ailit$>inluding ammonia lines

Proteti5e

1I1S 74922 .,,, (N et3)3

D

&

RSS

D Desi%n/ons!ru!ion rule

-Str it l$ *./0I&E/"I1 doument %or internal use onl$3 "!is doument ma$ not be reprodued or distr ibuted it!out pr ior ri tten appro5al % rom t!e *orporate

Respons ible *are %untion-3 *op$rig!t R!odia3

6ersion 2 78 'anuar$ 2994 &ate o% appliat ion: 7 'une 2994 &R* 77;


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APPE$DI 3 6 is! o' senarios an( sa'e%uar(s resul!in% 'ro) ris anal+ses 8RA9

RA

SCE$ARIO$o.

I$DEPE$DE$T

$ECESSARYA$Dsu''iien! auses

DESCRIPTIO$OFSCE$ARIO

Causes Un?an!e( e,en! E''e!sConse=uenes pS In(epen(en!pre,en!i,e or pro!e!i,e sa'e%uar(s RRCRA 4 73 0ailure o% 33333 irulation pump P 33333

23 0ailure o% 33333 pressure ontroller PI*L33

L rise in tube all temperature 333 rea!or ou!er?all pun!ure(L6apours and aerosols o% !ot> toi and %lammablesubstanes released into %ailit$3.5er 79 ategor$ 7 aidents (se5erit$ N ,) O /odeat!s

H Pre5enti5e

"I1 ;7;24 1, (N 7


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SCE$ARIORA

Case $o.

I$DEPE$DE$T$ECESSARYA$Dsu''iien! auses

DESCRIPTIO$OFSCE$ARIOCauses Un?an!e( e,en! E''e!s

Conse=uenespS In(epen(en!

pre,en!i,e or pro!e!i,e sa'e%uar(sRRC

RA 4 73 Internal orrosion o% e!anger E 33L L toi> orrosi5e gases enter steam iruit L s!ea)

irui! piere( ou!si(e on!ain)en! enlosureLMiture o% toi> orrosi5e> %lammable gases releasedinto atmosp!ere.5er 79 ategor$ 7 aidents (se5erit$ N ,) O /odeat!s

H Pre5enti5e

PI1A 42722 A, (N 79 bar): *lose Q*6 47998 PI1S 4272; S,, (N 72 bar) : *lose ,S6 ;7;


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APPE$DI 6 E>a)ple o' I0S 2 and I0S ;) !i! are t!e solesa%eguard %or ertain senarios3 .ne o% t!e to sa%eguards mar?ed -- ill need to be seleted as an I0Ssa%eguard3

6ersion 4 is used to %inis! t!e !oie: sa%eguard is seleted as sa%eguard I0S 4 in pre%erene to sa%eguard =as it o5ers more senarios and is in5ol5ed earlier in t!ese senarios3

6ersion < !ig!lig!ts senarios %rom t!e ris? anal$ses (R1) !i! do not $et !a5e I0S sa%eguards (nongre$senarios) and sa%eguards mar?ed -- %rom !i! t!e remaining I0S sa%eguards %or t!e %ailit$ ill beseleted3

6ersion 8 s!os t!e %inal seletion3


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APPE$DI 5 6 E>a)ple o' IFS i!e)s orrespon(in% !o IFS sa'e%uar(s

IFS $o.

RS $o.

DESCRIPTIO$

OFIFS SAFEGUARD Para)e!erssee REFESHEET E=uip)en! Proe(ures Sa'e!+ ins!ru!ionssee REFESHEET S!a'' au!


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IFS $o.RS $o.

DESCRIPTIO$OF

IFS SAFEGUARD

Para)e!erssee REFESHEET

E=uip)en! Proe(ures Sa'e!+ ins!ru!ionssee REFESHEET

S!a'' au!


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APPE$DI 6 E>a)ple o' a "Re'le> s


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APPE$DI 0 6 is! o' sa'e%uar(s orrespon(in% !o re%ula!or+ re=uire)en!s 8RR9

RE;UIRE#E$T

$o.REGUATORYRE;UIRE#E$T

DESCRIPTIO$OFSCE$ARIOUn?an!e( e,en! 6 Causes

E''e!s Conse=uenespS

PREE$TIEORPROTECTIEsa'e%uar(

orrespon(in% !o re=uire)en!sRRC

RR1 -"!e %oundations o% t!e ammonia

storage tan? s!all be adapted to resistan eart!qua?e de%ined %or t!e regionto a5oid rupture o% pipes it!in t!etan?3-

@nanted e5ent N Rup!ure o' D$ 2& line on liquidp!ase o% ammonia storage tan? or rup!ure o' s!ora%e!an*ause N Eart!qua?eE%%ets N Release o% ammonia gas and aerosol intoatmosp!ereEstimated number o% deat!s 79 (se5erit$ N *)

C Pre5enti5e

1ntiseismi onstrution ensuring integrit$ o% t!e %ailit$>

inluding ammonia linesProteti5e

1I1S 74927 S,, (N 2< ppm): *losure o% essoe sa%et$

5al5e at base o% storage tan? (antiseismi onstrutionensures t!at t!e 5al5e remains %untional): no! !aen in!oaoun! as t!e storage tan? itsel% ould rupture

1I1S 74922 .,,, (N


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RR3 -iquid p!ase lines s!all be %itted it!

ori%ie plates inside t!e tan? to reduet!e lique%ied gas %lo rate to t!eminimum te!niall$ aeptable to t!eusers o% t!e produt-3

@nanted e5ent N Rup!ure o' D$ 2& line on liquid

p!ase o% ammonia storage tan?*ause N Eart!qua?e> bro?en legs or ot!erE%%ets N Release o% ammonia gas and aerosol intoatmosp!ereEstimated number o% deat!s 79 (se5erit$ N *)

C Proteti5e

&/ 7< alibrated ori%ie plate elded inside storage tan?3


5al5e at base o% storage tan? (antiseismi onstrutionensures t!at t!e 5al5e remains %untional)

1I1S 74922 .,,, (N


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RE;UIRE#E$T






RR5 -"!e storage tan? s!all be plaed in a

sealed retention d$?e (bund) Ldesigned and implemented su! t!atan$ ater in t!e basin %rom an$ sourema$ be eliminated3-

@nanted e5ent N i=ui( a))onia lea%rom

storage tan?*ause N 1llE%%ets N Release o% ammonia gas and aerosol intoatmosp!ere ompounded b$ %ailure to retain liquid(lea? %rom retention basin or insu%%iient 5olume dueto presene o% ater)3Estimated number o% deat!s 79 (se5erit$ N *)

C Pre5enti5e

&esign o% retention basin

Proedure to !e? absene o% ater in basin and drain i%

neessar$3

Regular test %or lea? tig!tness o% d$?e (bund)

Proteti5e

&/ 7< alibrated ori%ie elded inside storage tan?3


5al5e at base o% storage tan? (antiseismi onstrutionensures t!at t!e 5al5e remains %untional)

1I1S 74922 .,,, (N

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Drc_sp_drc 11-35 Ps Guide Important for Safety Items_eng