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Webinar ”The Challenges of Managing the Safety Life Cycle” 2-3 pm Thursday, August 15, 2013 Host: Rick Stanley Former chairman of the API Subcommittee on Pressure Relieving Systems and the API Subcommittee on Instrumentation and Control Systems. Over 30 years of process industry experience managing , developing and implementing SIS standards and practices Register now at: https://attendee.gotowebinar.com/register/884335258304514764 8 Powered By: Takeaways from this webinar series include : Understanding the impact of implementing the Safety Life Cycle on the culture of your facility , across disciplines Identifying common obstacles to effectively implementing the Safety Life Cycle The tools and strategies that can effectively overcome these obstacles How you can transcend the negative perceptions of compliance by using the Safety Life Cycle to drive efficient and more profitable operations Aligning your facility with ANSI/ISA-84 & IEC61511 standards can appear to be an insurmountable task. It doesn’t have to be. Join us August 15 th for the start of the free webinar series: “Process Safety Life Cycle Management: Best Practices and Processes You Should Adopt” to learn how to transform your current process safety program to deliver intelligent and integrated safety solutions that can directly affect the bottom line, while simultaneously improving process and personnel safety. Designing, operating and maintaining safe operations in the process industry is no easy feat. The challenge is amplified by increasing compliance costs and leaner operations. To remain competitive, managers in the process industry must standardize compliance activities, develop & track safety performance indicators, and secure sufficient resources to close gaps.

Process Safety Life Cycle Management: Best Practices and Processes

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Learn how to transform your current process safety program to deliver intelligent and  integrated safety solutions that can directly affect the bottom line, while simultaneously improving process and personnel safety.

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Page 1: Process Safety Life Cycle Management: Best Practices and Processes

Webinar”The Challenges of Managing the Safety Life Cycle”

2-3 pm Thursday, August 15, 2013Host: Rick Stanley• Former chairman of the API Subcommittee on Pressure Relieving Systems and the API Subcommittee on Instrumentation and

Control Systems.• Over 30 years of process industry experience managing , developing and implementing SIS standards and practices

Register now at: https://attendee.gotowebinar.com/register/8843352583045147648

Powered By:

Takeaways from this webinar series include : Understanding the impact of implementing the Safety Life Cycle on the culture of your facility , across disciplines

Identifying common obstacles to effectively implementing the Safety Life Cycle

The tools and strategies that can effectively overcome these obstacles

How you can transcend the negative perceptions of compliance by using the Safety Life Cycle to drive efficient and more profitable operations

Aligning your facility with ANSI/ISA-84 & IEC61511 standards can appear to be an insurmountable task. It doesn’t have to be.

Join us August 15th for the start of the free webinar series: “Process Safety Life Cycle Management: Best Practices and Processes You Should Adopt” to learn how to transform your current process safety program to deliver intelligent and integrated safety solutions that can directly affect the bottom line, while simultaneously improving process and personnel safety.

Designing, operating and maintaining safe operations in the process industry is no easy feat. The challenge is amplified by increasing compliance costs and leaner operations. To remain competitive, managers in the process industry must standardize compliance activities, develop & track safety performance indicators, and secure sufficient resources to close gaps.

Page 2: Process Safety Life Cycle Management: Best Practices and Processes

Process Safety Life Cycle Management: Best Practices and Processes

The Challenges of Managing the Safety Life Cycle

Practical. Simple. Cost Effective.

Page 3: Process Safety Life Cycle Management: Best Practices and Processes

Today’s Topics

• Why We’re Here• Current Challenges of Safety Life Cycle Management • A Solution: ProSys DR

Page 4: Process Safety Life Cycle Management: Best Practices and Processes

Why We’re Here

Basic Investigative Findings No or poor hazards analysis No clear definition of protective system requirements Poor design, maintenance and procedures

Phillips 66Pasedena, TX23 DeadCost > $ 1B

BPTexas City, TX15 DeadCost > $ 2B

Union CarbideBophal, India< 3,787 DeadCosts > $ 1B

19921984

2005

Petróleos de Venezuela 42 DeadCost > $ 2B

2012

Review of general industry practices show that these root causes were not uncommon

Page 5: Process Safety Life Cycle Management: Best Practices and Processes

Protection Layers

Potential initiating causes

Undesired event Protection LayersPrevention

Process DesignBasic Process Control SystemsSafety Critical Process AlarmsSafety Instrumented Systems

MitigationMechanical Mitigation Systems

Fire and Gas SystemsPlant Emergency

Community Emergency

Implementing and maintaining protective layers requires a team effort.From the Plant Manager to the Technical Authority…to the Operator.

Page 6: Process Safety Life Cycle Management: Best Practices and Processes

Evolution of Regulations and Standards

OSHA Reg. 1910.119ISA S 84

OSHA Recognizes

ISA S84

19961992 2000

IEC 61511

2003

ANSI/ISA S84

2004

OSHA – 1910.119 Process Safety Management of Highly Hazardous ChemicalsIEC 61511 Recognized as world standard on Safety Instrumented SystemsISA S 84 “Application of Safety Instrumented Systems for the Process Industries”ANSI / ISA S84.01 - 2004 * Replaces ISA 84 - 1996 - OSHA has recognized ISA S84 as representing good practices for protective instrumentation

OSHA’s National Emphasis ProgramDirective CPL 03-00-010 Oil RefineriesDirective 10-05 (CPL2) Chemical NEP

Regulations are a means, not the end, in running a safe operation.

Page 7: Process Safety Life Cycle Management: Best Practices and Processes

Safety Life CycleIEC 61511 provides a formalized way to manage Instrumented Protective Systems throughout a plant’s service life

Page 8: Process Safety Life Cycle Management: Best Practices and Processes

DocumentationOperations Maintenance

Safety Function Design

Management Obligations

The Challenge: Effectively managing the Safety Life Cycle requires teamwork between mulitple disciplines, departments, and even companies. Resources are limited.

Lack of Continuity

Disparate data

PaperworkOverload

Inconsistent reporting formats

Lack of Sharing between

Organizations

Loss of DataPersonnel Turnover

Complicating Factors

Safety Function ID

Workplace Safety

Initiative Overload

Page 9: Process Safety Life Cycle Management: Best Practices and Processes

Managing the Safety Life Cycle Conceptual Process Design Hazard and Risk Analysis Apply non-SIS Protection

Layers

Define SIL Develop SRS Perform SIS Concept

Design

Perform SIS detailed design Install, commission, and

test Establish Operation and

Maintenance Procedures

Establish Operate & Maintain Procedures

Pre-startup Safety Review

SIS Startup, Maint, Periodic Testing

Process Safety Manager

Process Engineer I&C Engineer

Project Engineer Engineering Contractor Project Construction Contractor

Plant Maintenance Plant Engineer Engineering Contractor

Plant Operations and Maintenance Plant Engineer

SLM Process Organization

PHA LOPA

SRS FSA

Design Documentation

Establish Operation and Maintenance Procedures

Pre-startup Safety Review

SIS Testing and Validation

FAT Proof Testing Integrity

Compliance Activities

HAZOP

SIS

Engineering

Operations

Maintenance

Silos Industry Tools