Guidelines for Managing Abnormal Situations

ISBN-13: 9781119862871 / Angielski / Twarda / 2022 / 272 str.

Center for Chemical Process Safety (CCPS)

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Table of Contents vList of Figures xiList of Tables xiiiList of Example Incidents xvAcronyms and Abbreviations xviiGlossary xxiAcknowledgments xxxiPreface xxxvDedication xxxvi1 Introduction 11.1 Purpose and Scope of the Book 11.2 What Are Abnormal Situations? 21.3 The Business Case for Managing Abnormal Situations 41.4 Content and Organization of the Book 52 Process Safety and Management of Abnormal Situations 92.1 Impact on Process Safety 92.2 The Case for Positive Management of Abnormal Situations 112.3 Adverse Outcomes of Abnormal Situations 132.4 Importance of Training for Abnormal Situations 222.5 Safety Culture and the Management of Abnormal Situations 233 Abnormal Situations and Key Relevance to Process Plant Operations 273.1 Focus Areas for Abnormal Situation Management 273.1.1 ASM Research Areas 273.1.2 Additional Focus Areas 303.2 Abnormal Situations Affecting Process Plant Operations 323.2.1 Process Control Systems -the First Line of Defense 403.2.2 Frontline Operators 443.3 Management of Abnormal Situations and Links to Risk Based Process Safety 483.3.1 Commitment to Process Safety 503.3.2 Understand Hazards and Risk 503.3.3 Manage Risk 503.3.4 Learn from Experience 513.3.5 Additional RBPS Elements Related to Management of Abnormal Situations 523.4 Procedures and Operating Modes for Managing Abnormal Situations 533.4.1 General Principles for Procedure Development 533.4.2 Operating Modes 583.4.3 Types of Material Being Processed 784 Education for Managing Abnormal Situations 854.1 Educating the Trainer 854.2 Primary Target Populations for Training 864.2.1 Front-line Operators 874.2.2 Operations Management 894.2.3 Plant Engineers/Technicians 904.2.4 Process Safety Engineers 914.2.5 Design Engineers 914.2.6 Environmental Health, Safety and Security (EHSS) Personnel 1004.2.7 Technical Experts 1004.2.8 Other Parties 1024.3 Guidance for Organizing and Structuring Training 1024.3.1 Organization of Training 1024.3.2 Structure of Training Topics 1034.3.3 Skills and Competencies of Trainers 1064.4 Summary 1065 Tools and Methods for Managing Abnormal Situations 1075.1 Tools and Methods for Control of Abnormal Situations 1085.2 Predictive Hazard Identification 1125.2.1 Hazard Recognition for Abnormal Situations 1135.2.2 HIRA Approach to Hazard Prediction 1135.3 Process Control Systems 1155.3.1 Process Trend Monitoring 1175.3.2 Alarm Management 1195.3.3 Big Data 1225.3.4 Advanced Diagnostics and Artificial Intelligence 1235.4 Policies and Administrative Procedures 1245.4.1 Expectations of Policies and Administrative Procedures 1265.4.2 The Relationship of Policies to Abnormal Situation Management 1265.4.3 Process Metrics 1295.5 Operating Procedures 1305.5.1 Standard Operating Procedures 1315.5.2 Emergency Procedures 1325.5.3 Transient Operation Procedures 1335.5.4 Preparing Written Procedures 1345.6 Training and Drills 1355.7 Ergonomics and Other Human Factors 1395.7.1 HMI (Human Machine Interface) System 1405.7.2 Control Room Ergonomics/ Human Factor Assessment 1425.7.3 Crew Resource Management 1435.8 Learning from Abnormal Situation Incidents 1475.9 Change Management 1495.9.1 Management of Change Guideline Tools 1505.9.2 Management of Organizational Change 1535.9.3 Pre-Startup Safety Review 1546 Continuous Improvement for Managing Abnormal Situations 1556.1 General 1556.2 Landscape of Available Metrics for Improvement 1566.3 Abnormal Situations and Incident Investigations 1586.4 Auditing 1596.5 Management Review and Continuous Improvement 1626.6 Summary 1637 Case Studies/lessons Learned 1657.1 Case Study 7.1 - Air France, 2009 1667.1.1 Background 1667.1.2 Incident Overview - Air France AF 447 1697.1.3 Speed Measurement on A330 Aircraft 1697.1.4 A330 Flight Control Systems 1717.1.5 Airbus Pitot Tube History 1737.1.6 The Incident - Air France AF 447 1737.1.7 Lessons Learned Relevant to Abnormal Situation Management 1787.1.8 Epilogue 1827.2 Case Study 7.2 - Texaco Refinery, Milford Haven, Wales, July 1994 1847.2.1 Background 1847.2.2 Incident Overview - Texaco Milford Haven 1857.2.3 Outline Process Description of Milford Haven Refinery 1867.2.4 Controls and Instrumentation 1887.2.5 Some Relevant History at the Refinery 1897.2.6 The Incident 1907.2.7 Immediate Cause 1937.2.8 Lessons Learned Relevant to Abnormal Situation Management 1937.2.9 Epilogue 1987.3 Case Study 7.3 - The Hickson And Welch Fire, 1992, Castleford, UK 1997.3.1 Background 1997.3.2 Incident Overview - Hickson and Welch fire 2007.3.3 Outline Process Description of Meissner Plant 2017.3.4 History of Meissner Plant Prior to Incident 2037.3.5 The Incident 2057.3.6 Immediate Causes 2067.3.7 Lessons Learned Relevant to Abnormal Situation Management 2077.3.8 Epilogue 210Appendix A Managing Abnormal Situations - Training Materials 211Appendix B ASM Joint Research and Development Consortium: Background 213References 215Index 225

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The Center for Chemical Process Safety (CCPS) has been the world leader in developing and disseminating information on process safety management and technology since 1985. The CCPS, an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has published over 100 books in its process safety guidelines and process safety concepts series, and over 30 training modules through its Safety in Chemical Engineering Education (SAChE) series. CCPS is supported by the contributions and voluntary participation of more than 200 companies globally.