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Course Material
1. Overview of Process Safety
2. Compliance with Standards
3. Process Hazard nalysis!. Standard Operatin" Procedures
#. Safe $or% Procedures
&. Mechanical 'nte"rity7. Management of Change
(. uditin" Process Safety Systems
). *mer"ency +esponse Procedures
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,. Mana"ement of Chan"e
Process Safety
Management for
Biofuels
-his material was produced under "rant SH1)!,)/)&/03& from the Occupational Safety and Health
dministration .S. epartment of 4a5or. 't does not necessarily reflect the views or policies of the .S.
epartment of 4a5or nor does mention of trade names commercial products or or"anizations imply
endorsement 5y the .S. 6overnment.
2) C0+ 1)1/.11) 7l8
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0li95orou"h +eactor Series
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:ellows at 0li95orou"h
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Of
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Mana"ement of Chan"e
1. System esi"n
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Management of change (MOC)
mana"ement system for ensurin" thatchan"es to processes are properly
analyzed documented and
communicated to affected personnel.
efinitions
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process chemicals
technolo"ye;uipment
procedures
facilities
Management of Change
Types of MOC
http://var/www/apps/conversion/tmp/scratch_1/MOC%20TABLE%203%20Types%20of%20Changes.dochttp://var/www/apps/conversion/tmp/scratch_1/MOC%20TABLE%203%20Types%20of%20Changes.doc -
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Process Safety Information
1910.119l!"!
'f a chan"e covered 5y this para"raph results in a
chan"e in the process safety information re;uired5y para"raph 7d8 of this section such information
shall 5e updated accordin"ly.
http://www.osha.gov/pls/oshaweb/owalink.query_links?src_doc_type=STANDARDS&src_unique_file=1910_0119&src_anchor_name=1910.119(l)(4)http://www.osha.gov/pls/oshaweb/owalink.query_links?src_doc_type=STANDARDS&src_unique_file=1910_0119&src_anchor_name=1910.119(l)(4) -
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Management of Change
1. $ritten MOC procedures
2. MOC
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Management of Change
#. Mana"ement of Chan"e lo"
&. Mana"ement of Chan"e form,. Periodic monitorin" 7field chec%s8
(. uditin"
System esi"n
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Management of Change
Training
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2. -heMana"ement of Chan"e
7MOC8 Process
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MOC
http://var/www/apps/conversion/tmp/scratch_1/Revised%20MOC%20Form,%20July%206.xlshttp://var/www/apps/conversion/tmp/scratch_1/Revised%20MOC%20Form,%20July%206.xls -
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#eplacement in $in%
6ate valve:utterfly valve :all valve
ctuated 5utterfly
valves
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Management of Change
Training on the Change
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Management of Change
1. -echnical 5asis
2. 'mpact on safety and health
3. Modifications to operatin" procedures
!. >ecessary time period for the chan"e
#. uthorizations
MOC &O#M
http://var/www/apps/conversion/tmp/scratch_1/Detailed%20MOC%20Guidelines%20_7July%20(25).xlshttp://var/www/apps/conversion/tmp/scratch_1/Detailed%20MOC%20Guidelines%20_7July%20(25).xls -
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1. Technical Basis for
Change
'hat(
)o*(
'hy(
'here(
'hen(
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+. Impact on Safety , )ealth
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-. Mo%ifications to
Operating Proce%ures
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". ecessary time perio% for the
change
MOC
http://var/www/apps/conversion/tmp/scratch_1/Revised%20MOC%20Form,%20July%206.xlshttp://var/www/apps/conversion/tmp/scratch_1/Revised%20MOC%20Form,%20July%206.xls -
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Management of Change
/. uthoriations
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23&II4 #O53S 2
#3SPOSIBI5ITI3S
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Chan"e
Ori"inators
23&II4 #O53S 2
#3SPOSIBI5ITI3S
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#O53S 2 #3SPOSIBI5ITI3S
+eviewers
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MOC Coordinator
#O53S 2 #3SPOSIBI5ITI3S
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#O53S 2 #3SPOSIBI5ITI3S
PSM Mana"er
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#O53S 2 #3SPOSIBI5ITI3S
*mployees
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Senior Mana"ement
#O53S 2 #3SPOSIBI5ITI3S
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Changes to co6er
un%er MOC1. Capital improvement pro?ects
2. Maintenance wor% orders
3. 'nstrument chan"e re;uests!. Spare parts control
warehousin" and distri5ution
#. *n"ineerin" chan"e re;uests
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Changes to co6er
un%er MOC
&. +esearch and development 7+@8 process
chan"e recommendations
,. Company specifications(. CS pro"rammin" chan"e re;uests
). Process e9periments or tests conducted in the
manufacturin" plant.
1/. Contractor service a"reements
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1. Aeep it simple
2. O5tain acceptance
3. 0ield test the system
!. Provide ade;uate trainin"
4ui%ing Principles for
Implementation
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3. Maintainin" an effective
Mana"ement of Chan"e7MOC8 Process
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1. Monitor effectiveness
2. udit3. emonstrate commitment
Maintaining an MOC
System
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3ffecti6eness of MOC System
$ey Performance In%icators
1.-he num5er of MOCs performed each month.
2.-he monthly percenta"e of wor% re;uests that are
classified as a chan"e.3.-he percenta"e of emer"ency MOCs.
!.-he avera"e 5ac%lo" of MOCs.
#.-he avera"e calendar time from MOC ori"ination
to MOC authorization.
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3ffecti6eness of MOC System
u%iting
1. ocumentation completed
2. -rainin" conducted
3. Procedures reviewed for updatin"
!. PreStartup Safety +eviews
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Management of Change
PreStartup Safety +eviews
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PreStartup Safety
+eview
-he term prestartup safety review
7PSS+8 means a final chec% prior
to initiatin" the use of process
e;uipment.
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PSS+
't is applyin" a systematic method to
confirm that the startup team andprocess e;uipment are prepared for
startup.
efinitions
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ny chan"e 5ein" made to an e9istin" process
or
any new facility 5ein" added to an e9istin" processor facility
or
any other activity a facility desi"nates as needin" a
prestartup safety review.
efinitions
-ri""er *vent
> h
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>onchan"e
-ri""er *vent
Wh Sh ld PSSR b
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When Should a PSSR be
Performed
1. Capital project approved
2. Changes to Operating Facilities occur
. !emporar" Changes #Fli$borough%
&. Restart of an idled process
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1. #egularly e6aluating in%ustry process
safety relate% inci%ent reports an% ho*PSS# *as potentially in6ol6e% in the
situation.
Best Practices PSS#
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+. 8sing electronic %ataases for
capturing past PSS#%ocumentation.
Best Practices : PSS#
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-. Performing PSS#s on
selecte% critical maintenanceacti6ities.
Best Practices : PSS#
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". In6ol6ing many %ifferent
*or;ers in the PSS#process.
Best Practices : PSS#
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/. Selecting a PSS# team lea%er
*ho is some*hat remo6e% fromthe specific pro
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=. Sho*ing open management
support for the importance ofPSS#.
Best Practices : PSS#
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Compilin" and sin" a
PSS+ Chec%list
Chec;l
ist
http://var/www/apps/conversion/tmp/scratch_1/PSSR%20long%20form.ppthttp://var/www/apps/conversion/tmp/scratch_1/PSSR%20long%20form.ppthttp://var/www/apps/conversion/tmp/scratch_1/PSSR%20long%20form.ppthttp://var/www/apps/conversion/tmp/scratch_1/PSSR%20long%20form.ppthttp://var/www/apps/conversion/tmp/scratch_1/PSSR%20long%20form.ppthttp://var/www/apps/conversion/tmp/scratch_1/PSSR%20long%20form.ppthttp://var/www/apps/conversion/tmp/scratch_1/PSSR%20long%20form.ppthttp://var/www/apps/conversion/tmp/scratch_1/PSSR%20long%20form.ppthttp://var/www/apps/conversion/tmp/scratch_1/PSSR%20long%20form.ppthttp://var/www/apps/conversion/tmp/scratch_1/PSSR%20long%20form.ppt -
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Compilin" and sin" a
PSS+ Chec%list-he role of the PSS+ pro"ram is
to provide a second layer of
protection around the
mana"ement of chan"e element.
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Compilin" and sin" a
PSS+ Chec%list
ependin" upon the specific
processes materials intermediatesand products involved the PSS+
chec%list ;uestions should 5e
customized to match the facility.
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+emainin" Course
Material1. Overview of Process Safety
2. Compliance with standards
3. Process Hazard nalysis!. Standard Operatin" Procedures
#. Safe $or% Procedures
&. Mechanical 'nte"rity7. Management of Change
(. uditin" Process Safety systems
). *mer"ency response procedures