NEBOSH Process Safety Management Element 3 Process Safety & Hazard Control Video # 3 of 4

Process Safety Management: Element 3 - Process Safety Hazards and Controls

Overview of Process Safety Hazard Control

• The video introduces the third element of NEBOSH Process Safety Management, focusing on process safety hazards and controls. It outlines that this element consists of eight sub-elements, starting with operating procedures.

Importance of Operating Procedures (3.1)

• Emphasizes the critical role of operating procedures in ensuring safety within hazardous industries, particularly during startup and shutdown phases. Safe practices are essential in sectors like oil and gas.

• Highlights the need for personal competency in developing safety policies and procedures, encouraging viewers to assess their ability to create effective operational guidelines.

Design Considerations for Safety

• Stresses that a safe operating environment (SOE) must be established during the design phase to prevent hazards from becoming uncontrollable. Poor design can lead to significant safety risks.

• Discusses how design parameters such as pressure, temperature, and flow rate should be optimized to maintain control over processes and avoid unsafe conditions. Reminds viewers to remember "PTF" (Pressure, Temperature, Flow).

Purpose of Standard Operating Procedures (SOPs)

• SOPs serve as vital tools for informing operators about process safety hazards while outlining control systems and acceptable operating conditions including allowable ranges for operations.

• Different types of SOPs are necessary for various scenarios such as startup/shutdown processes, maintenance tasks, emergency responses, and handling abnormal operations or deviations from standard practices.

Development Involvement in SOP Creation

• The development of SOPs is a collaborative effort involving operators, maintenance teams, contractors, and design engineers—collectively referred to as OMD (Operators-Maintenance Contractors-Design). This teamwork ensures comprehensive input into procedure creation.

• Operators' involvement is crucial because they provide insights that ensure written procedures accurately reflect actual practices on the ground; this alignment helps enhance overall safety compliance during operations.

Involving Operators in Safety Procedures

Importance of Operator Engagement

• Involving operators in safety procedures fosters a sense of ownership, leading to increased acceptance and adherence to protocols. Engaging them respects their role and emphasizes that safety is their responsibility.

Limitations of Operator Participation

• Not all operators can participate in drafting Standard Operating Procedures (SOPs), which may limit the effectiveness of individual performance. It's crucial to recognize these limitations when developing SOP content.

Key Components of SOP Development

• SOPs must clearly outline the purpose, process steps, equipment, materials used, hazards involved, and necessary controls. Clarity on "who," "what," "where," "how," and "why" is essential for effective implementation.

Visual Aids and Authorization

• Incorporating visual aids such as pictures, flow charts, checklists, and ensuring worker authorization are critical elements in SOP development. Accessibility to Personal Protective Equipment (PPE) should also be ensured.

Drafting and Revising Procedures

• The procedure drafting process involves creating an initial draft followed by trials and revisions until clarity is achieved. Including operators in this process helps ensure comprehensibility.

Learning from Past Incidents

Importance of Training with Real Examples

• Utilizing real incident videos during training can highlight the importance of understanding procedures. For instance, the West Fertilizer Company incident serves as a cautionary tale about procedural adherence.

Maintaining Current SOP Standards

• Regular reviews are necessary to keep SOPs current and accurate. This includes analyzing deviations from expected processes and conducting oversight through retrospective analysis.

Challenges in Following Safety Protocols

Factors Affecting Compliance

• Several factors impact operators' ability to follow recipes: time pressure, workload levels, staffing issues, training adequacy, supervision quality, human error potential, and technical problems.

Consequences of Deviating from Procedures

• Deviating from established operating procedures can lead to organizational drift and major disasters affecting both personnel safety and company reputation.

The Role of Training in Emergency Situations

Response Time During Alarms

• Quick response to alarms is critical; historical examples like Three Mile Island illustrate how delays can exacerbate situations due to operator confusion or lack of training.

Enhancing Operator Preparedness

• Ensuring operators are well-trained reduces unplanned downtime while improving overall process safety performance. Knowledgeable staff who understand each step contribute significantly to maintaining safe operations.

Understanding Startup and Shutdown Processes

Types of Startups/Shutdown Procedures

• There are various types of startups/shutdown processes: planned (with predetermined control sequences), unplanned (due to malfunctions), emergency (in hazardous situations), stage one or delayed startups/shutdown scenarios require careful management for safety compliance.

Understanding Startup and Shutdown Procedures

Importance of Planning in Shutdowns

• Discusses the two-stage process for startup and shutdown, emphasizing the need for a planned approach to manage issues that arise during operations.

• Highlights the significance of predetermined sequences in planned shutdowns, which are essential for maintenance and risk assessment linked to product supply.

Risks Associated with Unplanned Shutdowns

• Explains that unplanned shutdowns due to equipment malfunction or power failure can be dangerous, especially without a proper plan in place.

• Notes that human factors play a critical role in managing high-risk situations during shutdown processes.

Safety Protocols During Startups

• Stresses the necessity of having written procedures (SOPs) for both startups and shutdowns to ensure safety and compliance.

• Outlines reasons why startups and shutdown processes can be hazardous, including potential adjustments to plant controls that may not reflect the full status of operations.

Pre-startup Safety Review Considerations

• Emphasizes the importance of conducting pre-startup safety reviews, considering factors like management changes and mechanical preparations.

• Lists additional points such as electrical testing and calibration of alarms that must be addressed before starting operations.

Communication and Training in Plant Operations

• Underlines the critical nature of communication and training regarding safety checks during plant shutdown procedures.

• Introduces safety-critical performance standards necessary for ensuring operational integrity within hazardous environments.

Performance Standards in Process Safety Management

Understanding Safety Critical Systems

• Defines safety-critical systems as elements designed to prevent or limit major accidents, stressing their importance in maintaining asset safety.

Assessing Performance Standards

• Discusses how performance standards are established based on design criteria expectations, highlighting their role in evaluating system effectiveness.

Management of Change Considerations

• Addresses how even minor changes can have significant consequences if not properly managed through established performance standards.

Understanding the PHA Process and Farsi Model

What is a PHA?

• A Process Hazard Analysis (PHA) is a systematic evaluation of hazards, their causes, and potential consequences related to a specific process.

• Techniques used in PHA may include methods like Hazard What If analysis.

Introduction to Farsi

• The term Farsi stands for:

• F: Functionality

• A: Availability

• R: Reliability

• S: Survivability

• I: Interdependency

• Remembering the acronym can help in understanding performance standards.

Importance of Performance Standards

• Performance standards are crucial for managing hazards throughout the lifecycle of a plant, ensuring that critical risk control systems remain effective.

Components of the Farsi Model

Functionality

• Functionality refers to the tasks an argument must perform and how its performance can be measured against preset standards, such as water flow rates in fire suppression systems.

Availability and Probability of Failure on Demand (PFD)

• Availability indicates the proportion of time a system is operational under expected conditions.

• Key terms include:

• Probability of Failure on Demand (PFD) – likelihood that a component fails when needed.

• Mean Time Between Failures (MTBF) – average time between failures in equipment or systems.

Safety Integrity Level (SIL) and Instrumented Systems

Safety Integrity Level (SIL)

• SIL measures safety integrity based on average probability that safety functions perform correctly under specified conditions over time.

• There are four levels in SIL, with level one being the lowest and level four being the highest.

Safety Instrumented Systems (SIS)

• SIS consists of three components:

• Sensors

• Logic solvers

• Final elements which execute physical actions based on sensor inputs.

Reliability and Survivability

Reliability

• Reliability assesses how likely a system will operate successfully when required, often expressed through metrics like PFD or MTBF.

• Target values might specify acceptable downtime percentages for detectors within set periods.

Survivability

• Refers to a system's ability to function under adverse conditions post-event, such as surviving fires or explosions during emergencies. This ensures continued operation until safe refuge is available.

Interdependencies Among Systems

Understanding Interdependencies

• Interdependencies highlight how certain systems rely on others for functionality; e.g., fire detection systems depend on emergency power sources.

Questions for Reflection:

• Consider interactions among various safety systems like blow down deluge and emergency shutdown protocols; what dependencies exist?

Utilities Related to Process Safety Management

Uses of Steam in Industry

• Steam serves multiple purposes including:

• Heating processes directly or indirectly.

• Humidification needs in production environments.

• Atomization processes essential in pharmaceutical applications.

Properties of Saturated Steam:

• The boiling point varies with pressure; saturated steam releases heat efficiently compared to hot water, making it vital across industries like food processing and pharmaceuticals.

Understanding Steam and Water Management in Industrial Processes

The Importance of Condensate Management

• Condensate from formations, such as steam, can contain up to 3.5% water, which may affect heat efficiency in piping systems.

• Professionals like reliability engineers and process engineers should grasp the concept of streaming processes involving saturated and superheated steam.

Hazards Associated with Steam Systems

• Thermal expansion due to temperature increases can lead to structural changes in vessels; this is a critical safety concern.

• Water hammer occurs when high-pressure water strikes fixed objects within pipelines, causing vibrations that can lead to damage.

Control Mechanisms for Water Hammer

• Effective design and maintenance of piping systems are essential for controlling water hammer by managing condensate removal and maintaining proper steam quality.

• Proper venting during draining operations is crucial to prevent vacuum formation, which can create additional hazards.

Hydrostatic Testing Considerations

• Hydrostatic testing is vital for identifying leaks; it involves pressurizing vessels with water while ensuring safe venting practices are followed.

• Monitoring weight changes during hydrostatic tests helps assess vessel expansion and integrity under pressure.

Biological Risks in Cooling Towers

• Bacteria such as Legionella thrive in cooling tower waters, posing health risks through aerosolized droplets; contamination must be managed effectively.

• Issues like fungal growth in paper manufacturing highlight the importance of maintaining clean water sources used in industrial processes.

Inert Gas Applications for Safety

• Inert gases are utilized to displace oxygen in confined spaces, reducing fire risks during maintenance activities.

• Purging with nitrogen or other inert gases creates non-explosive atmospheres necessary for safe operational conditions.

Understanding Flammable Materials and Safety Risks

Flammable Mixtures and Atmosphere Control

• Flammable materials combined with oxygen can create hazardous mixtures; purging is essential to mitigate risks.

• Different gases, such as carbon monoxide and nitrogen, require careful insulation of storage vessels to prevent dangerous contact at varying temperatures.

• Introducing inert gases into tank air spaces reduces the risk of flammable or explosive atmospheres during filling or emptying processes.

Firefighting and Inert Gases

• Inert gases are effective in extinguishing fires by displacing oxygen, which is crucial for safety in industrial settings.

• Nitrogen is often used as a coolant in pipeline operations due to its low temperature properties, facilitating maintenance work.

Electricity Hazards in Industrial Settings

Basics of Electric Current

• Understanding electric circuits involves recognizing current flow, voltage differences, and resistance; Ohm's Law (V = I * R) is fundamental.

• There are two types of current: Direct Current (DC), which flows steadily in one direction, and Alternating Current (AC), which changes direction periodically.

Effects of Electric Current on the Body

• The impact of electric current varies significantly; thresholds for perception start at 0.5 mA while higher currents can lead to severe health risks like loss of consciousness or cardiac arrest.

• Muscle contractions caused by electric shocks may prevent individuals from letting go of live wires, increasing danger during electrical accidents.

Risks Associated with Arc Flash

Causes and Consequences

• Arc flashes occur when conductors are separated improperly; loose connections can lead to violent sparks that pose serious hazards.

• These events not only threaten worker safety but also risk igniting flammable dust or causing significant equipment damage.

Prevention Strategies

• Regular inspections and proper wiring practices are critical to minimize arc flash incidents; understanding common causes helps improve workplace safety protocols.

• Static electricity buildup on non-conductive surfaces can lead to dangerous situations if not managed properly.

Understanding Static Electricity and Its Implications in Industrial Settings

The Creation of Static Charge

• Friction between two materials can create static electricity, often through the transfer of electrons when they are pressed together.

• Grounding methods are essential to prevent static charges that could lead to explosions, especially in industries like oil and gas where electrostatic discharges pose significant risks.

Electrostatic Charges and Their Effects

• Materials can develop a potential difference due to static charge, which may result in sparks capable of igniting flammable substances.

• The piezoelectric effect occurs when heat or stress is applied to certain crystals, causing them to generate an electric charge.

Types of Static Discharges

• Various types of static spark discharges include brush discharge and conical file discharge; these can occur during processes involving flowing liquids or friction contact.

• Common scenarios for generating static electricity include conveyor belts, pouring liquids, grinding operations, and even movement on insulated surfaces.

Control Measures for Static Electricity

• Bonding and grounding techniques are critical for controlling static electricity in industrial settings. Fixed objects provide permanent connections while movable objects require careful handling.

• Special considerations must be made for liquids transported through pipes; using glass-lined containers or tantalum plugs helps mitigate risks associated with static charges.

Power Outages and Safety Procedures

• Power outages can have severe consequences in facilities like refineries; strategies such as uninterrupted power supplies (UPS) or generators are vital for maintaining operations during outages.

• Generators should be properly maintained and tested to ensure readiness during emergencies; adequate fuel supply is also crucial.

Dangerous Substances: Physical States and Risks

• Dangerous substances exist in three physical states: gas, liquid, and solid. Each state presents unique containment challenges.

• Gases pose higher risks due to their flammability compared to liquids. Solids' risk levels depend on their form—fine powders can ignite more easily than larger pieces.

Specific Hazards Associated with Dust

• Finely divided metals mixed with air create highly flammable atmospheres. For example, aluminum dust poses significant dangers when combined with other elements.

• Incidents involving pyrophoric materials highlight the importance of proper maintenance practices; accumulation of combustible dust can lead to catastrophic failures if not managed correctly.

Understanding Chemical Hazards and Reactions

Ignition Sources and Explosive Substances

• Explosive substances can ignite when mixed with oxygen in the right proportions, requiring minimal ignition energy which can be generated by heat, shock, or electric charge.

• Common oxidizing agents include nitric acid, hypochlorite, and hydrogen peroxide; these substances easily react with others to produce combustion.

Flash Points and Flammable Liquids

• The flash point is the lowest temperature at which a liquid emits enough vapor to ignite. Categories of flammable liquids are defined based on their flash points and boiling points.

• Category one flammable liquids have a flash point below 23°C; gasoline is an example that ignites within a specific range of air mixture.

Reaction Hazards

• Understanding chemical reactions involves knowing what affects reaction rates and whether they will occur, especially in confined spaces where conditions can change rapidly.

• Factors such as temperature and pressure significantly influence reaction rates; higher pressures allow gas molecules more freedom to react.

Catalysts and Energy Considerations

• Catalysts lower activation energy for reactions but can lead to uncontrollable reactions if not managed properly. The extent of the reaction depends on the energy available.

• Exothermic reactions release heat (e.g., combustion), while endothermic reactions absorb heat from their surroundings.

Thermal Runaway Reactions

• Thermal runaway occurs when exothermic reactions accelerate due to incorrect reactant volumes or specifications leading to dangerous situations like overpressure or equipment damage.

• Consequences of thermal runaway include loss of containment, toxic releases, and catastrophic failures in chemical processes.

Bulk Storage Operations

• There are various types of tanks used for liquid storage including fixed roof tanks, floating roof tanks, pressurized tanks, etc., each with unique hazards associated with them.

• Overfilling tanks poses significant risks such as fluid overflow leading to ignition sources; proper instrumentation is crucial for monitoring levels accurately.

Tank Design and Failure Modes

Foundation and Structural Considerations

• Discusses the importance of circular ring beam foundation design for tanks, particularly in high wind areas, emphasizing the use of anchor boards to prevent failure.

• Highlights various failure modes for tank shells, including creep stress, thermal shock, and brittle fracture. It stresses the need to consider these factors during design.

Material Behavior Under Stress

• Explains how materials can be categorized as ductile or brittle based on their response to strain; ductile materials deform while brittle materials break under stress.

• Introduces stress corrosion failure due to hydrogen embrittlement and thermal shock from rapid temperature changes that can lead to cracking.

Fatigue Failure Mechanisms

• Describes fatigue failure as a result of repeated load applications that do not individually cause failure but accumulate over time, leading to various types of fatigue such as thermal or contact fatigue.

• Notes that cyclic stress or tensile stress can induce fatigue failures in storage tank fittings due to external factors like wind load and vibrations.

Safety Measures in Tank Design

• Emphasizes the need for thorough research when designing bulk storage tanks for hazardous substances, considering safety distances for people and property.

• Discusses essential design features such as ventilation systems to manage internal pressure variations during filling operations.

Operational Protocols and Risk Management

• Stresses the importance of monitoring systems to prevent overfilling tanks, including alarms that alert operators when levels exceed safe limits.

• Addresses risks associated with mobile road tankers during liquid transfer operations, highlighting the necessity for secure connections between tankers and storage vessels.

Floating Roof Tanks: Advantages and Risks

• Explains floating roof tanks' designs which minimize vapor emissions by maintaining headspace above liquids; discusses two types: internal and external floating roofs.

• Warns about potential issues like water loading on roofs due to heavy rainfall affecting buoyancy if not properly designed.

Fire Hazards and Protection Systems

• Identifies fire hazards related to fixed roof tanks due to static charges or ignition sources; emphasizes proper fire protection systems are crucial.

• Concludes with a note on bundling designs needing at least 110% capacity of total contents for effective containment against spills.

Understanding Process Safety Management

Importance of Tank Maintenance and Safety

• Emphasizes the need for effective maintenance to prevent catastrophic failures in tanks, highlighting the importance of bonding and inspection.

• Discusses the significance of isolating walls and functional safety systems for draining tanks, stressing that technical understanding enhances safety processes.

• Warns about potential hazards from lightning strikes which can ignite volatile substances, leading to catastrophic failures through induced sparking or punctures.

Control Measures for Hazardous Environments

• Suggests using lightning conductors at strategic points on tank roofs to mitigate risks associated with flammable vapors.

• Encourages research into safe storage practices for hazardous materials, considering factors like chemical properties and reactions with water.

Assessing Risks in Warehousing

• Highlights the necessity of understanding physical properties and potential reactions of stored substances, referencing Material Safety Data Sheets (MSDS).

• Identifies various ignition sources such as electrostatic discharge and emphasizes assessing local topography's impact on safety.

Security and Storage Practices

• Discusses legal requirements regarding separation distances for hazardous materials and access provisions for emergency services.

• Stresses the importance of proper inventory management to minimize exposure risks by segregating incompatible materials effectively.

Final Thoughts on Process Safety Management

• Recommends continuous learning about warehousing controls to enhance safety measures against ignition sources.

• Concludes with a call to action for professionals in process safety management to deepen their knowledge through available resources.