Frank Joop Executive Director Global Business Development · Executive Director Global Business...
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Safety in the Engineering Enterprise Frank Joop Executive Director Global Business Development Oslo November 16/17, 2010
Transcript of Frank Joop Executive Director Global Business Development · Executive Director Global Business...
Safety in the Engineering Enterprise
Frank Joop
Executive Director Global Business Development
Oslo November 16/17, 2010
Topics
Plant Operational Safety Management
– Issues
– Safety Categories
Customer and sample use cases
– Corrosion management
– Leakage detection and repair (LDAR)
– Explosion impact studies
– Area Classification
– Escape Route Simulation
– Automated HAZOP Analysis
– Safety Instrument Systems (SIS)
– SmartPlant Enterprise for Owner / Operators (SPO)
Lock out tag out (LOTO)
Facility Safety Management
Summary
Safety is at the Forefront
Plant Operational Safety Management
- To prevent this from happening -
OSHA - Operational Safety Management
Elements
1. Employee Participation
2. Process Safety Information
3. Process Hazard Analysis
4. Operating Procedures
5. Training
6. Contractors
7. Pre-Startup Safety Reviews
8. Mechanical Integrity
9. Hot Work Permits
10. Management of Change
11. Incident Investigation
12. Emergency Planning Response
13. Compliance Audits
14. Trade Secrets
SmartPlant Engineering Enterprise
coverage
Plant Operational Safety Management
- Understanding the Issues -
No such thing as a 100% safe plant
Accept Risk will be there
Key is to identify and mitigate Risk to an acceptable level
– Learn from the past
– Start early with safety – build it into the design
– Balance between cost and risk level
– Make Safety a part of everyone’s culture
Cannot put a price tag on safety
– lost lives', environment, assets, credibility, etc…
Increasing challenge as plants get larger and processes more complex
Plant Operational Safety Management
- Safety Categories -
Process SafetyEnsure that if the process deviates from the design intent it will go into a safe
state.
HAZOP and Risk Assessment and mitigation are the key components
SmartPlant Engineering Enterprise can provide:
– Design rules to ensure safe practices
– Risk assessments with automated HAZOPs
Personnel SafetyCreate a design that allows safe operation in such areas as operational
spacing, personal protection, escape routes, training, etc.
SmartPlant Engineering Enterprise can provide:
– Create, maintain and manage space allocations for escape routes
– Verify, through rules, spacing to allow equipment operation
– Verification of regulatory practices (OSHA/EPA ) with the rules engine
Plant Operational Safety Management
- Safety Categories -
Facility Safety
Design the facility to be safe in abnormal situations such as explosions
– fire proofing, structural integrity, equipment positioning and spacing
SmartPlant Engineering Enterprise can provide:
– Impact analysis by interfacing with third parties
– Through rules and area classification, verify the fire proofing and other safety design
criteria
Environmental safety
Offer capabilities to monitor, manage and contain the process to avoid
impact on the environment
SmartPlant Engineering Enterprise can provide:
– Use of the logical and physical plant model to define inspection points
– Design Rules to contain the process exception impact e.g. bund sizing, drainage, etc..
The $1-10-1000 Rule
Making the right decision early
– Cost of finding error during design $1
– Cost of finding error during the checking process $10
– Cost of finding the error in the construction/commissioning $1000
Drive consistency in distributed projects
Comply with company and regulatory standards
Help capture knowledge and experience
Piping
Instrumentation
Equipment
Electrical
P&ID
Safety in the Engineering Enterprise
Use Cases
Plant Operational Safety Management –
Use Case
Operational safety
SECCO, China
Leakage Detection and Repair (LDAR)
Indentify & Number LDAR Test Points on over 2000 PID’s
Automate Detection requirements procedures with EDMS
– frequency, locations , scheduling
Identify trends
– Allowable leakage values
Interface with CMMS for repair work orders
– Leakage discovery and time to repair records, and post repair re-exam
Interface with Reliability Monitoring Systems
Reduce Risk of Plant Incident caused by Leakage
Inspection Points automatically identified
using SmartPlant P&ID
LDAR
SPF维修历史记录 实施
工单优先级计划工单
维护工作循环
SPPID&SPF
基本信息
检测结果
Basic data
检验检测
数据
检测数据检测任务
建议
泄漏点
检验任务
RBI
修理后复测
分析策略
A B C D E
1
2
4
3
5风险矩阵
工程数据管理系统
EDMS
LDAR - Systems Interoperability
LDAR Inspection Procedures
LDAR Examples
Tagged Valves
Repair Process
Plant Operational Safety Management –
Use Case
Facility Safety
Bechtel and Gexcon
Gas explosion impact study for off-shore facility
Impact studies to ensure stable and safe design
Identify possible design modification to increase safety and lower risks
Identify escape routes
Integration with FLACS
Validating Design for Gas Explosion
Impact
Data
Export
FLACS
Analysis
Design
Feedback
Safe Design
Rules
Minimize
Changes
CMR Gexcon
Analysis Model
Explosion Impact Study
Plant Operational Safety Management –
Use Case
Process / Personnel Safety
BP Bulwer Island, Australia
Corrosion Monitoring Package
Improve Corrosion Inspection testing procedures
Automation of Manual processes
Reduce “on plant” time by Inspection Team
Provided improved analysis and reporting
Provide improved productivity & cost savings
Reduce Risks
CMP Overview
Plant Operational Safety Management –
Use Case
Process Safety / Personnel Safety
Rules based Hazardous Area Classification
Associate classification with plant items on the P&ID
Automatically create the zones around the plant items based on standards / project
practices in SmartPlant 3D
Rules verify if equipment placed within the zones are of the right classification
Zones are associated so will move when item is moved
Create the associated deliverables such as area classification layout
Add zones in the 3D model not associated to plant items such as ditches etc.
Hazardous Area Classification Examples
Hazardous Area Classification with SP
Enterprise
This is just and example to show the powerful rules that can help make a safe
design from the start.
Rules and workflows are open, extendible, customizable.
Scenario
Assign the area classification to the control valve on the P&ID (Class 1 Div 1).
Model and place the control vale in the 3D model
Based on the project table the zone (cylinder in this case) is placed around the
control valve and the classification Class 1 Div 1 is associated with that space.
Place an electric panel in the zone with a lower classification
Show the error/warning message
Move the control vale and with that move the zone and execute the rules
against the new plant items in the new located zone to verify classification.
Plant Operational Safety Management –
Use CaseProcess Safety
Automated HAZOP analysis with SP P&ID and SPPS
Identify the deviations from the design intent in abnormal situations
Pre-check the P&ID for safety devises and design methods
Create course and effect matrix
Create the course and consequence report
Provide the data for the engineer to make risk mitigation decisions
Manage the design action as a result of the mitigations
Provide the SIL factors to help determine the SIS
Provide auditable and consistent analysis that can be made part of the design
activities to minimize the late finding/changes
SmartPlant Process Safety analyses SmartPlant
P&IDs following the Hazop methodology
Node 2
Action responses are input directly into the database
The action sheet is viewed from the database preventing duplicated documents.
Plant Operational Safety Management –
Use Case
Personnel Safety
Emergency Escape route management with SmartPlant 3D
Define and assign spaces for escape in emergency situations in the 3D model
Clash detection in case items obstructing free passes
Training using the 3D model
Creating layout/deliverables identifying the routes for approval and records
Safe Exit
Plant Operational Safety Management –
Use Case
SmartPlant Enterprise for Owner / Operators (SPO)
Lock Out / Tag Out (LOTO) ensures that equipment is isolated until
maintenance or service work has been completed.
Interoperability across operations systems to facilitate decision making
responding to incidents
Management of Plant Changes
Plant Operational Safety Management
Process Safety
Designing the Safety Instrument System (SIS) with SPI
Community emergency response – Emergency broadcasting, evacuation
Plant emergency response – Evacuation procedures
Prevention and mitigation – Mechanical, non-SIS
Prevention and mitigation –SIS
Control and Monitoring like BPCS
Basic process design
to be inherently safe
Intrinsically safe equipment and wiring shall not be capable of releasing sufficient electrical or
thermal energy under normal and abnormal conditions to cause Ignition of a specific atmospheric
mixture in its most easily ignited concentration
Work process
Intrinsically Safe calculation results
Intrinsically Safe calculation report
Custom SIS report (SPI Browser)
Design Safety Instrument Systems with SPI
Supporting the work process
Determining the safety system
Managing the circuit data
Calculating the energy
Documenting the design
Benefits
Single environment to design all instrument systems
Consistent documentation
Custom rule to support the work process with that reduce errors and drive
standard compliance
Support of work process and associated calculations to ensure IS systems.
SUMMARY
The Price Tag on Safety
Cannot assign a price tag to Safety
– Life
– Environment
– Plant/production
– Corporate image
– More
Lowering the Risk
– Smart Designs
– Access to current information
– Intelligent Plant to monitor changes and the effect on safety
SmartPlant Safety Management can Help
SmartPlant Safety EngineeringAdditional Solution Scenarios
Process Safety– Pipe line verification
– Design Review rules (strait pipe length before e.g. measuring items)
– Relieve vale management
– Spacing rules
– Pipe Stress Analysis
– Equipment failure analysis
– Lock-out Tag-Out
Personnel Safety– Spacing rules
– Permit Management
– Location tracking
– Resource Management
Facility Safety– None Conformities and Waivers
– Back-up Systems
– Fire Proofing
– Drilling compliance management
Environmental safety– Leak management
– HAZOP
– Containment design
– Impact studies
More……………………
Summary
Lessons learned
Use SmartPlant Enterprise Solutions, with the inbuilt rules to help make the
right decisions throughout the facility Lifecycle
Utilize the information to mange leaks, tag-outs, corrosion
Validate design with solution such as FLACS
Be pro-active with Safety
– Design it into the plant
– Make it part of the culture
– Share lesions learned in a corporate knowledgebase
Rules based design provides the possibility for Safer / Lower Risk Plants in
Operations
Impact on corporate image and value
DESIGN SAFETY INTO YOUR PLANT
WITH SMARTPLANT ENTERPRISE
