Presentation on theme: "Safety Driven Performance 2013"— Presentation transcript:
1Safety Driven Performance 2013 Developing and Maintaining Relief System Design Documentation as an Evergreen ProcessMarie BakerRelief System Optimization Technical ManagerLloyd’s Register Energy America’s, Inc.
2AgendaOverview of 29 CFR – How this standard applies to relief systemsRelief system design documentation methodology – Benefits of using a system based approach for relief systemsDeveloping an evergreen process – The importance of an evergreen process for relief systemsOptimization of relief system design documentation – Helpful hint for optimizing data
329 CFR 1910.119 – Process Safety Management of Highly Hazardous Chemicals Intended to prevent or minimize consequences of catastrophic releases of toxic, reactive, flammable or explosive chemicalsApplies to facilities that meet the following requirements:Process involving a chemical at or above the specified threshold quantities listed in appendix AProcess involving a flammable gas or liquid with a flashpoint below 100 °F on site in a quantity of 10,000 pounds or more
429 CFR 1910.119 – 14 Elements of Process Safety Management Employee participationProcess safety informationProcess hazard analysisOperating proceduresTrainingContractorsPre-startup safety reviewsMechanical integrityHot work permitManagement of changeIncident investigationEmergency planning and responseCompliance auditsTrade secrets
529 CFR 1910.119 (d) – Process Safety Information Highly hazardous process chemical informationPhysical dataToxicity informationProcess technology informationBlock flow diagram/Process flow diagram (PFD)Process chemistrySafe upper/lower limitsProcess equipment informationProcess & instrumentation diagrams (P&ID)Equipment design codes and standardsRelief system design and design basisTalk about subsection ii – The employer shall document that equipment complies with recognized and generally accepted good engineering practices (RAGAGEP)
6What is Relief System Design Basis Relief system design basis – documents how the loads and sizes of the relief system were determinedIncludes but not limited to:Overpressure scenariosRelief load calculationsAssumptions
7Relief System Documentation Methodology – System based approach System based approach is the preferred methodologySystem comprised of:Protected equipmentInterconnected pipingRelief device(s)Relevant equipment included in documentationPressure sourcesInlet control valvesRestriction orificesLocked open/closed valvesDetermine how to evaluate the relief systems – device vs. system approachSystem – based on equipment rather than relief device
8Benefits of System Based Approach All equipment is evaluatedPressure VesselsHeat ExchangersPumpsTanksCaptures equipment without overpressure protectionPresents a total picture of the systemAll equipment is evaluated not just equipment with a relief device.Analysis should be performed on unprotected to determine if protection is needed.
10Relief System Documentation Methodology Overpressure Scenario EvaluationIncludes all systems, protected and unprotectedAll scenarios evaluated for each systemRationale provided for eachFor all credible overpressure scenariosCalculations performedRequired relief loadRequired orifice areaInlet and outlet pressure dropsAny assumptions should be documentedFull evaluation of all potential overpressure scenarios performed for each system and rationale provided documenting why credible/not credible.This is good practice as it can eliminate questions later about specific cases (why or why not considered), PHA/HAZOP questions can be answered quickly and easilyCredible scenarios should have relief rate calculated or explanation of why no load calculated – nominal or same as another case (MAWP < Pressure > MAAP)Good practice to calculate area and pressure drops for all cases not just controlling. Largest rate may not be the largest area or have the highest pressure drop.
11Recommended Relief System Documentation API 521 recommended documentationProtected equipment informationOverpressure scenario analysisRelief conditionsRelief device manufacturer/modelRelief load calculationsEffluent locationFull listing provided in API 521 Section 4.4
12Benefits of Relief System Documentation Process Consistent documentationFollowing same standards/guidelines on all projectsAll equipment is evaluatedProtected and unprotectedInformation is detailedScenario rationales fully explainedCalculations includedAssumptions stated
13Benefits of Relief System Documentation Process Current information available to the facilityProcess Hazard Analysis (PHA)Hazard and Operability (HAZOP)Turnaround (TAR) planningInternal and external audits
14Steps to Evergreen the Relief System Documentation – Step 1 Define/develop baseline for relief system designRevalidationPartial or fullRecommended when documentation is scarce at a facilityGap analysisBased on overpressure scenariosBased on documentationDesign verification
15Steps to Evergreen the Relief System Documentation – Step 2 Develop a process for updating the relief system design basisWho will be responsible for relief system documentationIn-house group or third party contractorHow information will get to the responsible groupHow and where information will be storedElectronically or paper copiesCentral location or multiple copies spread throughout facilityWhen will relief systems group be brought in on projectsWho will have access to the information and to what extentCommunication to all areas of the plant about the importance of keeping the relief system design and documentation up to date.
16Steps to Evergreen the Relief System Documentation – Step 3 Implement the process and continually improve on itWorkflow process written in detailLook for ways the process can be more efficientWho is responsible for keeping up to date on new standardsAs people and job responsibilities change, there needs to be a succession plan or detailed documents on the process and how it has been working.As standards change, there needs to be a process to keep up with those as well. Each time the standards are published there is more information and more detail on the existing information.
17Optimizing Relief System Design and Documentation Master system files stored as PDF electronicallyLimits access for unauthorized changesProvides venue for anyone needing the informationCan easily be viewed in meetingsUtilizing database softwareProvides storage of dataVarious software available depending on facility requirementsSoftware can provide users with different levels of accessibilityInformation is searchable by plant personnelSpecific information can be easily extracted