Process Hazard Analysis: Study Enhancement

Keith V. Farrell, MS ChE

PSM Coordinator

INVISTA, Orange Plant

10/27/2009 1

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Beginning Thoughts

The Three Laws of TechnologyThe Three Laws of Technology

By Arthur C. Clark

• When an engineer states that something is possible, he is almost certainly RIGHT. When he states that something is impossible, he is very probably WRONG.

• Any sufficiently advanced technology is indistinguishable from magic.

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Study Objectives

• Federal Requirements

• Companies Requirements

• Tools

• Training

• “Bringing all Together”

• Cost and Savings

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Federal Requirements

• OSHA CFR Title 29 §1910.119

– Process Safety Management of Highly Hazardous Chemicals

• EPA CFR Title 40 Part 68

– Chemical Accident Prevention Provisions

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Company Requirements

• Accuracy and Precision

• Compliance

• Speed

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Accuracy and Precision

• Right Recommendations

• Vague Recommendations

• Constrictive Recommendations

• Wrong Recommendations

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Speed

• TIME IS MONEY!!!!

• Too Quick of a Pace for the Study

– Team Fails by Being Rushed

– Missed Consequences

• Too Slow of a Pace for the Study

– Team Fails by Tiring of Thinking

– Missed Consequences

– Unnecessary Consequences (Whines)

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Tools

• Willing People

• Deep Knowledge

• Accessible Information

• Archiving and Accessing Captured Information for Study

• Equipment

• EIS

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Tools

• People, Knowledge, Information, Computer Programs, Archiving Information, Access to Information

• Typical for All PHAs

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Tools: Equipment

• Displaying Information

– Eye strain

– Comfort

• Markups of P&IDs

– To Keep the Team on Same “Page”

– Verbal Directions of Nodes

– Not Quick

• Derailing the Thought Train

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Tools: Equipment, cont.

•Monitors for each Team Member & Space remaining for P&IDs

– Same Page Issue

– Quick Editing

– Comfortable

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Tools: Equipment, cont.

•Document Camera to Project Drawings

– Use Basic Marked Drawings

– Lower Eye Strain

– Faster Information Recognition

– Visual Data preferred

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EIS

Electronic Information Systems (EIS)

• What

• Where

• When

• How

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EIS: Defined.

• Databases

• Information Availability

• Benefits

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EIS: Databases

• PSI necessary for PHA

– PSI

– Alarms/ SIS

– SOLs

– PSV

– Process Control Points

– Process Information Points

– Procedures

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EIS

• Proper Form of Database

– Accessibility

– User Friendly

– Updateable

– Protectable

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WHAT FORM OF DATABASE?

• Software Needs Questions

– Stable

– Quick

– Ease of Use

– Expandable

– Software Life-span

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Accessibility and User Friendly

• Questions to ask

– Who needs access

– What level of access

– Any training necessary

– Who will fix problems

– Who will maintain information

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Expandable and Software Life-span

• What will be your PSI needs in the Future

• What software will be there at that time

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Cost Analysis

• Equipment

• Software

• Training for Leaders

• Savings!!!!!!!

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Equipment

• Seven Monitors @ $150 each

– Two – Operators

– Three– Engineers

– Two – Other Skill Sets

• One Document Camera @ $2000

• Other Minor Equipment @ $300

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Software

• PHA Software (Current)

• Adobe Writer @$650

(Based on the assumption you have a computer and associated operational software)

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Total Cost

• Equipment = $3350

• Software = $650

• Total = $3850

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Training for Leaders

Necessary Training

•Basic Leader Development (In House?)

•Basic Instructor Development (In House?)

•Negotiating Development (In House?)

Items to consider

•Basic Interview Development

•Basic Speakers Development

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Savings!!!!!!!

• Time for Initial Studies

– Normal; 5 to 8 weeks

– With Enhancements; 3 to 4 weeks

• Using one Operator & two Engineers; combined cost $270/hr

• Time Savings ~$11,300 per study

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Savings, cont.

• Time for Revalidation Studies

– Normal; 2 to 4 weeks

– Enhanced; 1 to 8 study days

• Using one Operator & two Engineers; combined cost $270/hr

• Time Savings ~ $11,300 for each study

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The Bottom Line

• Hardware and Software Total = $3350

• Savings per study = ~ $11,300

• Net Saving for the first Study = $7,450

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Last Comment

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DesiredDesiredResultsResults

PSIPSI

PH

AP

HA

Changes

Changes

THANKS

•Mary Kay O’Connor Process Safety Center

•Dr. M. Sam Mannan

•INVISTAKeith V. Farrell

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A Few Questions????

Questions

Questions

Questions

Questions

Questions

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