Process safety reviews

W. B. Howard, Case Histories of Two Incidents Following Process Safety Reviews, Proceedings of the Thirty-first Annual Loss Prevention Symposium, AIChE, New York, 1997. 

Process Safety Review Procedures for Capital Projects... 

The "Capital Projects Design Review Procedures" element of process safety management assures that the design, the equipment and the construction are properly reviewed for all new projects. Process safety review procedures should be involved with the project from its inception. One method of illustrating the various phases of a project is shown in Figure 8.1 (Figure 5-1 from CCPS, 1989a). 

Process Safety Review Procedures for Capital Projects Process and Equipment Integrity Human Factors Company Standards, Codes, and Regulation Employee Participation Pre-Startup Safety Review Mechanical Integrity Hot Work Permit Emergency Planning and Response Trade Secrets Planning for Emergencies... 

Describe the process changes including plant operation that have been made since the previous process safety review... 

Process Safety Reviews for Capital Projects. The need for process safety reviews of capital projects, whether new or revised facilities, has been a recognized feature of engineering organizations. These reviews must be comprehensive and systematic. It is best to do reviews early to avoid costly modifications later. Not only do process hazards need to be identified and addressed by the design, but broader issues should be considered, such as ... 

Supported by the PSMT, the line organization develops a structured approach for performing process hazard analyses on a repetitive basis. One effective way to do this is to organize knowledgeable facility personnel into ad hoc Process Safety Review (PSR) teams. These teams, supplemented by outside specialists as required, are responsible for studying all processes, identifying all potential hazards, and recommending appropriate corrective or control measures. 

All review sessions should be recorded using a personal computer (PC). Word processing software should be used for the report narrative write-up. A computer software spreadsheet, prepared for process safety reviews, should be used for all HAZOP and What-If reviews. It facilitates speed, ease of use and maintains exact consistency in format. 

Subject Process Safety Reviews - Corporate Policy... 

Recent U.S.and Worldwide Legislation and our own Company policies recognize that process safety reviews are to be undertaken at our facilities. These reviews ensure that Health, Safety, and Environmental Protection are an integral part of our operations. Implementation of these policies will not only improve our process safety but lead to improved efficiencies and economics for the company that directly benefit our employees. 

The process requirements for both temperature and pressure should also be evaluated against the production equipment capabilities as part of the production equipment assessment. Normal operating conditions are used as a base case, but upset conditions should also be included as part of the evaluation. If venting is chosen to control unintended reactions, vent sizing calculations must be performed and peripheral equipment selected as needed. Experiments and simulations to determine consequences of unintended reactions and the interpretation of these experiments are documented as part of the production process safety review. 

The following important process safety review processes should be performed thoroughly during the process revamp project execution stages for a successful and sustainable... 

A "process safety review" is done before startup that includes a second check that aU other requirements have been met. Systems designed to meet aU these requirements should have a sufficiently low level of... 

Derived from S. P. Krivan, Avoiding Catastrophic Loss Technical Safety Audit and Process Safety Review, Professional Safety, February 21-26 (1986). 

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