Guidelines for Integrating Process Safety into Engineering Projects

There is much industry guidance on implementing engineering projects and a similar amount of guidance on Process Safety Management (PSM). However, there is a gap in transferring the key deliverables from the engineering group to the operations group, where PSM is implemented. This book provides the engineering and process safety deliverables for each project phase along with the impacts to the project budget, timeline and the safety and operability of the delivered equipment.

Table of Contents:
List of Figure xvii List of Tables xviii Acronyms and Abbreviations xx Glossary xxviii Acknowledgments xxxii Files on the Web xxxiv Preface xxxvi 1 INTRODUCTION 1 1.1 Background and Scope 2 1.2 Why Integrating Process Safety is Important 3 1.3 What Type of Projects Are Included? 5 1.4 Project Life Cycle 7 1.5 Relationship to Other Programs 10 1.6 Structure of this Document 13 2 PROJECT MANAGEMENT CONCEPTS AND PRINCIPLES 16 2.1 Common Principles and Structure 16 2.1.1 Statement of Requirements 16 2.1.2 Project Scope 17 2.1.3 Basis of Design 17 2.1.4 Project Budget 18 2.1.5 Project Plan 18 2.1.6 Project Life Cycle 19 2.2 Project Management 20 2.3 Project Governance 21 2.4 Types of Project 22 2.4.1 Greenfield Projects 22 2.4.2 Brownfield Projects 22 2.4.3 Retrofit / Expansion Projects 23 2.4.4 Control System Upgrade Projects 24 2.4.5 Demolition Projects 24 2.4.6 Management of Change Projects 24 2.4.7 Mothballing Projects 25 2.4.8 Re-Commissioning Projects 25 2.4.9 Restarting a Project 25 2.4.10 Post-Incident Projects 26 2.5 Project Organization 26 2.5.1 Pre-Project Team 26 2.5.2 Typical Project Team 27 2.5.3 Unit Based Team 28 2.5.4 Equipment Based Team 28 2.5.5 Site Based Team 28 2.5.6 Small Projects 28 2.5.7 Roles and Responsibilities 29 2.6 Strategies for Implementation 32 2.6.1 Contractor Selection 35 2.6.2 Engineering Only 36 2.6.3 Engineering and Procurement 36 2.6.4 Engineering, Procurement and Construction 36 2.6.5 Operation 37 2.6.6 Contractor Oversight 37 2.7 Risk Management 38 2.8 Project Controls 40 2.8.1 Planning and Progress 40 2.8.2 Estimates, Budgets and Cost Control 41 2.8.3 Reporting 41 2.8.4 Metrics 41 2.8.5 Action Tracking 42 2.8.6 Change Management 42 2.9 Other Considerations 43 2.9.1 Materials Management 43 2.9.2 Quality Management 43 2.9.3 Lessons Learned 43 2.9.4 Post-Project Close-Out 44 2.10 Stage Gate Reviews 44 3 FRONT END LOADING 1 46 3.1 Preliminary Hazard Identification 48 3.2 Preliminary Inherently Safer Design Review 49 3.3 Concept Risk Analysis 51 3.4 Other Activities 52 3.4.1 Process Safety and EHS Plan 52 3.4.2 Risk Register 52 3.4.3 Action Tracking 52 3.5 Stage Gate Review 53 3.6 Summary 54 4 FRONT END LOADING 2 56 4.1 Evaluation of Development Options 58 4.1.1 Hazard Identification 59 4.1.2 Preliminary Inherently Safer Design Review 59 4.1.3 Concept Risk Analysis 60 4.1.4 Selection of the Development Option 60 4.2 Further Definition of the Selected Option 63 4.2.1 Design Hazard Management Process 63 4.2.2 Preliminary Inherently Safer Design (ISD) 68 4.2.3 Hazard Identification and Risk Analysis (HIRA) 68 4.2.4 Engineering Design Regulations, Codes, and Standards 69 4.2.5 Design Philosophies/Strategies 70 4.2.6 Preliminary Facility Siting Study 71 4.2.7 Preliminary Fire and Explosion Analysis 72 4.2.8 Transportation Studies 72 4.2.9 Preliminary Blowdown and Depressurization Study 74 4.2.10 Preliminary Fire & Gas Detection Study 74 4.2.11 Preliminary Fire Hazard Analysis 74 4.2.12 Preliminary Firewater Analysis 75 4.2.13 Preliminary Security Vulnerability Analysis 75 4.2.14 Other Engineering Design Considerations 75 4.3 Other Activities 76 4.3.1 EHS and Process Safety Plan 76 4.3.2 Risk Register 76 4.3.3 Action Tracking 76 4.3.4 HIRA Strategy 76 4.3.5 Docum entation 77 4.3.6 Stage Gate Review 77 4.4 Summary 79 5 FRONT END LOADING 3 80 5.1 Evaluation of Development Options 82 5.2 Further Definition of the Selected Option 82 5.2.1 Design Hazard Management Process 84 5.2.2 Inherently Safer Design Optimization 85 5.2.3 Facility Siting and Layout 86 5.2.4 Refine Design Safety Measures 93 5.2.5 Set Performance Standards 94 5.2.6 Hazard Identification and Risk Analysis (HIRA) 95 5.2.7 Safety Assessments 102 5.2.8 Re-Evaluate Major Accident Risk 113 5.2.9 Finalize Important Safety Decisions 113 5.2.10 Finalize Basis of Design 113 5.3 Other Engineering Considerations 114 5.3.1 Asset Integrity Management 114 5.3.2 Quality Management 115 5.3.3 Contractor Selection 115 5.3.4 Brownfield Developments 116 5.4 Other Activities 116 5.4.1 EHS and Process Safety Plans 116 5.4.2 Risk Register 116 5.4.3 Action Tracking 116 5.4.4 Change Management 116 5.4.5 Documentation 117 5.4.6 Preparation for Project Execution 117 5.5 Case for Safety 119 5.6 Stage Gate Review 119 5.7 Summary 120 6 DETAILED DESIGN STAGE 121 6.1 Detailed Design 124 6.1.1 Design Hazard Management Process 124 6.1.2 Inherently Safer Design Optimization 125 6.1.3 Site Layout 126 6.1.4 Design Safety Measures 126 6.1.5 Set Performance Standards 127 6.1.6 Hazard Identification and Risk Analysis (HIRA) 127 6.1.7 Safety Assessments 128 6.1.8 Re-Evaluate Major Accident Risk 129 6.1.9 Other Design Reviews 129 6.2 Procurement 130 6.3 Asset Integrity Management 131 6.4 Other Process Safety Activities 132 6.4.1 Case For Safety 132 6.5 Other Project Activities 133 6.5.1 EHS and Process Safety Plans 133 6.5.2 Risk Register 134 6.5.3 Action Tracking 134 6.5.4 Change Management 134 6.5.5 Documentation 135 6.5.6 Constructability 136 6.5.7 Contractor Selection 137 6.6 Preparation for Construction 138 6.7 Preparation for Pre-Commissioning, Commissioning, and Startup 139 6.8 Stage Gate Review 140 6.9 Summary 141 7 CONSTRUCTION 143 7.1 Planning 146 7.2 Pre-Mobilization 147 7.3 Mobilization 149 7.4 Execution 150 7.4.1 Procurement 151 7.4.2 Fabrication 151 7.4.3 Safety Culture 151 7.4.4 Workforce Involvement 152 7.4.5 Stakeholder Outreach 152 7.4.6 Contractor Management 152 7.4.7 Transportation 153 7.4.8 Equipment and Materials Handling 153 7.4.9 Hazard Evaluation 154 7.4.10 Engineering Design 156 7.4.11 Safe Work Practices 157 7.4.12 Operating, EHS and Process Safety Procedures 159 7.4.13 Training and Competence Assurance 159 7.4.14 Asset Integrity Management 160 7.4.15 Change Management 161 7.4.16 Emergency Response 162 7.4.17 Incident Investigation 163 7.4.18 Auditing 164 7.4.19 Performance Measurement 164 7.4.20 Operations Case for Safety 165 7.4.21 Pre-Commissioning 166 7.4.22 Mechanical Completion 170 7.4.23 Documentation 171 7.5 Other Project Activities 172 7.5.1 EHS and Process Safety Plans 172 7.5.2 Risk Register 172 7.5.3 Action Tracking 172 7.5.4 General Construction Management 172 7.6 De-Mobilization 173 7.7 Preparation for Commissioning and Startup 174 7.8 Final Evaluation and Close-out 175 7.9 Stage Gate Review 175 7.10 Summary 177 8 QUALITY MANAGEMENT 178 8.1 Design/Engineering 183 8.2 Procurement 186 8.3 Fabrication 187 8.4 Receipt 189 8.5 Storage and Retrieval 190 8.6 Construction and Installation 191 8.7 Operation 193 8.8 Documentation 194 8.9 Summary 194 9 COMMISSIONING AND STARTUP 196 9.1 Preparation 199 9.1.1 Planning 199 9.1.2 Safety 201 9.2 Operational Readiness 202 9.2.1 Pre-Startup Stage Gate Review 203 9.2.2 Operational Readiness Review 204 9.2.3 Start-Up Efficiency Review 207 9.3 Commissioning 208 9.3.1 Equipment Testing 209 9.3.2 Commissioning Procedures 211 9.4 Startup 213 9.4.1 Preparation for Startup 213 9.4.2 Calibration of Instruments and Analyzers 213 9.4.3 Startup with Process Chemicals/Fluids 214 9.5 Common Process Safety Elements 215 9.5.1 Hazard Evaluation 215 9.5.2 Safe Work Practices 216 9.5.3 Procedures 217 9.5.4 Training and Competence Assurance 217 9.5.5 Management of Change 218 9.5.6 Incident Investigation 219 9.5.7 Emergency Response 220 9.5.8 Auditing 221 9.5.9 Documentation 221 9.5.10 Performance Measurement 222 9.6 Other Project Activities 222 9.6.1 EHS and Process Safety Plans 222 9.6.2 Risk Register 223 9.6.3 Action Tracking 223 9.7 Performance Test Runs 223 9.8 Handover 224 9.9 Preparation for Ongoing Operation 225 9.10 Project Close-Out 226 9.10.1 Close Out Report 226 9.10.2 Post-Project Evaluation 226 9.11 Summary 227 10 OPERATION 228 10.1 Process Safety Management System 231 10.1.1 Process Safety Culture 233 10.1.2 Compliance with Standards 233 10.1.3 Process Safety Competency 233 10.1.4 Workforce Involvement 234 10.1.5 Stakeholder Outreach 234 10.1.6 Process Knowledge Management 234 10.1.7 Hazard Identification and Risk Analysis 234 10.1.8 Operating Procedures 235 10.1.9 Safe Work Practices 235 10.1.10 Asset Integrity and Reliability 236 10.1.11 Contractor Management 238 10.1.12 Training and Performance Assurance 239 10.1.13 Management of Change 239 10.1.14 Operational Readiness 239 10.1.15 Conduct of Operations 240 10.1.16 Emergency Management 240 10.1.17 Incident Investigation 240 10.1.18 Measurement and Metrics 241 10.1.19 Auditing 242 10.1.20 Management Review and Continuous Improvement 242 10.1.21 EHS and Process Safety Procedures 243 10.2 Other Project Activities 243 10.2.1 EHS and Process Safety Plans 243 10.2.2 Risk Register 243 10.2.3 Action Tracking 243 10.3 Technical Support 243 10.4 Performance Test Runs 244 10.5 Operation Stage Gate Rview 244 10.6 Post-Operational Review 245 10.7 Project Close-Out 246 10.8 Summary 246 11 END OF LIFE 247 11.1 Design for Decommissioning 249 11.2 Planning for Decommissioning 250 11.2.1 Engineering Survey 251 11.2.2 Hazard Evaluation 254 11.2.3 Hazardous Materials 254 11.2.4 Process Safety Plan 255 11.2.5 Utilities 255 11.2.6 Re-Engineering 256 11.3 Decommissioning Procedures 256 11.3.1 Late-Life Operations 257 11.3.2 Cessation of Production 258 11.3.3 Cleaning and Decontamination 258 11.3.4 Mothballed Facilities And Equipment 258 11.4 Deconstruction and Demolition 259 11.4.1 Deconstruction 259 11.4.2 Demolition 260 11.5 Process Safety for Decommissioning 261 11.5.1 Contractor Management 261 11.5.2 Safety Culture 262 11.5.3 Workforce Involvement 263 11.5.4 Stakeholder Outreach 263 11.5.5 Hazard Evaluation 263 11.5.6 Safe Work Practices 264 11.5.7 EHS and Process Safety Procedures 265 11.5.8 Training and Competence Assurance 266 11.5.9 Asset Integrity Management 267 11.5.10 Change Management 267 11.5.11 Operational Readiness Review 267 11.5.12 Emergency Management 268 11.5.13 Incident Investigation 269 11.5.14 Auditing 269 11.5.15 Disposal 270 11.5.16 Remediation 270 11.6 Other Project Activities 271 11.6.1 EHS and Process Safety Plans 271 11.6.2 Risk Register 271 11.6.3 Action Tracking 271 11.6.4 General Decommissioning Management 272 11.6.5 Stage Gate Reviews 272 11.7 Summary 274 12 DOCUMENTATION 275 12.1 Document Management 275 12.2 Process Knowledge Management 278 12.2.1 Front End Loading 1 Stage 278 12.2.2 Front End Loading 2 Stage 279 12.2.3 Front End Loading 3 Stage 280 12.2.4 Detailed Design Stage 281 12.2.5 Construction Stage 283 12.2.6 Commissioning and Startup Stage 286 12.2.7 Handover 287 12.2.8 Operation Stage 288 12.2.9 End of Life Stage 291 12.3 Summary 292 APPENDIX A. TYPICAL PROCESS SAFETY STUDIES OVER PROJECT LIFE CYCLE 293 APPENDIX B. PROJECT PROCESS SAFETY PLAN 295 APPENDIX C. TYPICAL HAZARD & RISK REGISTER 298 APPENDIX D. SAFETY CHECKLIST FOR PROCESS PLANTS 301 APPENDIX E. EXAMPLE OF SITE-SPECIFIC DECOMMISSIONING CHECKLIST / QUESTIONNAIRE 315 APPENDIX F. TYPICAL PROJECT DOCUMENTATION 322 APPENDIX G. STAGE GATE REVIEW PROTOCOL FOR PROCESS SAFETY 337 REFERENCES 365 INDEX 379