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Course Material 1.Overview of Process Safety 2.Compliance with Standards 3.Process Hazard Analysis 4.Standard Operating Procedures 5.Safe Work Procedures.

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Presentation on theme: "Course Material 1.Overview of Process Safety 2.Compliance with Standards 3.Process Hazard Analysis 4.Standard Operating Procedures 5.Safe Work Procedures."— Presentation transcript:

1 Course Material 1.Overview of Process Safety 2.Compliance with Standards 3.Process Hazard Analysis 4.Standard Operating Procedures 5.Safe Work Procedures 6.Mechanical Integrity 7.Management of Change 8.Auditing Process Safety Systems 9.Emergency Response Procedures

2 7. Management of Change Process Safety Management for Biofuels This material was produced under grant SH-19479-09-60-F-36 from the Occupational Safety and Health Administration, U.S. Department of Labor. It does not necessarily reflect the views or policies of the U.S. Department of Labor, nor does mention of trade names, commercial products, or organizations imply endorsement by the U.S. Government. 29 CFR 1910.119 (l)

3 Flixborough Reactor Series

4 Bellows at Flixborough

5 Of

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7 Management of Change 1. System Design

8 Management of change (MOC) A management system for ensuring that changes to processes are properly analyzed, documented, and communicated to affected personnel. Definitions

9 process chemicals, technology, equipment, procedures facilities Management of Change

10 Process Safety Information 1910.119(l)(4) If a change covered by this paragraph results in a change in the process safety information required by paragraph (d) of this section, such information shall be updated accordingly.

11 Management of Change 1. Written MOC procedures 2. MOC owner 3. Defined scope 4. Defined roles and responsibilities System Design System Design

12 Management of Change 5. Management of Change log 6. Management of Change form 7. Periodic monitoring (field checks) 8. Auditing System Design

13 Management of Change Training

14 2. The Management of Change (MOC) Process

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17 Replacement in Kind Gate valveButterfly valveBall valve Actuated butterfly valves

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20 Management of Change Training on the Change

21 Management of Change 1.Technical basis 2.Impact on safety and health 3.Modifications to operating procedures 4.Necessary time period for the change 5.Authorizations

22 1. Technical Basis for Change What? How? Why? Where? When?

23 2. Impact on Safety & Health

24 3. Modifications to Operating Procedures

25 4.Necessary time period for the change

26 Management of Change 5. Authorizations

27 DEFINING ROLES AND RESPONSIBILITIES

28 Change Originators DEFINING ROLES AND RESPONSIBILITIES

29 ROLES AND RESPONSIBILITIES Reviewers

30 MOC Coordinator ROLES AND RESPONSIBILITIES

31 PSM Manager

32 ROLES AND RESPONSIBILITIES Employees

33 Senior Management ROLES AND RESPONSIBILITIES

34 Changes to cover under MOC 1. Capital improvement projects 2. Maintenance work orders 3. Instrument change requests 4. Spare parts control, warehousing, and distribution 5. Engineering change requests

35 Changes to cover under MOC 6. Research and development (R&D) process change recommendations 7. Company specifications 8. DCS programming change requests 9. Process experiments or tests conducted in the manufacturing plant. 10. Contractor service agreements

36 1. Keep it simple 2. Obtain acceptance 3. Field test the system 4. Provide adequate training Guiding Principles for Implementation

37 3. Maintaining an effective Management of Change (MOC) Process

38 1.Monitor effectiveness 2. Audit 3. Demonstrate commitment Maintaining an MOC System

39 Effectiveness of MOC System Key Performance Indicators 1.The number of MOCs performed each month. 2.The monthly percentage of work requests that are classified as a change. 3.The percentage of emergency MOCs. 4.The average backlog of MOCs. 5.The average calendar time from MOC origination to MOC authorization.

40 Effectiveness of MOC System Auditing 1.Documentation completed 2.Training conducted 3.Procedures reviewed for updating 4.Pre-Startup Safety Reviews

41 Management of Change Pre-Startup Safety Reviews

42 Pre-Startup Safety Review The term pre-startup safety review (PSSR) means a final check prior to initiating the use of process equipment.

43 PSSR It is applying a systematic method to confirm that the startup team and process equipment are prepared for startup.

44 Any change being made to an existing process, or any new facility being added to an existing process or facility, or any other activity a facility designates as needing a pre-startup safety review. Definitions Trigger Event

45 Non-change Trigger Event

46 When Should a PSSR be Performed 1.Capital project approved 2.Changes to Operating Facilities occur 3.Temporary Changes (Flixborough) 4.Restart of an idled process

47 1. Regularly evaluating industry process safety related incident reports and how PSSR was potentially involved in the situation. Best Practices – PSSR

48 2. Using electronic databases for capturing past PSSR documentation. Best Practices - PSSR

49 3. Performing PSSRs on selected critical maintenance activities. Best Practices - PSSR

50 4. Involving many different workers in the PSSR process. Best Practices - PSSR

51 5. Selecting a PSSR team leader who is somewhat removed from the specific project involving the change. Best Practices - PSSR

52 6. Showing open management support for the importance of PSSR. Best Practices - PSSR

53 Compiling and Using a PSSR Checklist

54 The role of the PSSR program is to provide a second layer of protection around the management of change element.

55 Compiling and Using a PSSR Checklist Depending upon the specific processes, materials, intermediates, and products involved, the PSSR checklist questions should be customized to match the facility.

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57 Remaining Course Material 1.Overview of Process Safety 2.Compliance with standards 3.Process Hazard Analysis 4.Standard Operating Procedures 5.Safe Work Procedures 6.Mechanical Integrity 7.Management of Change 8.Auditing Process Safety systems 9.Emergency response procedures


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