EPC-UK

Introduction to Process Safety

The contents of the presentation are ©EPC-UK

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!Overview of Safety Systems

!Principles of Process Safety

!Application to External Industry

!Summary

Overview

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Process Safety Introduction

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Health and Safety Management

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‘A blend of engineering, management, and operational skills focused on

preventing catastrophic accidents; particularly explosions, fires, and toxic

releases associated with the use of chemical and petroleum products’

Centre for Chemical Process Safety

Process Safety Definition

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Flixborough

!Flixborough 1st June 1974;! Design modifications not

controlled

! 28 fatalities! 36 injuries on site! 56 injuries off site

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Seveso

!Seveso Disaster 10th June 1976;! Overheating of chemicals due to

plant shut down! No control readings on reaction

process! Release of toxic cloud over town of

Seveso

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!European Law;! Directive 82/501/EC, Seveso Directive I (1982)! Directive 96/82/EC, Seveso Directive II (1996)! Directive 2012/18/EU, Seveso Directive III (2012)

!UK Law;! HASAWA (1974)! Control of Industrial Major Accident Hazards (CIMAH)

1984 Regulations! Control of Major Accident Hazard Regulations

(COMAH) 1999 / 2015

EU Law and COMAH

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Is Process Safety Relevant to Me?

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Relevance to External Industry?

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Relevance to External Industry?

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!Tianjin !2015!Nitrocellulose Storage!800t Ammonium

Nitrate!798 injuries!173 Fatalities

https://www.youtube.com/watch?edufilter=NULL&v=993wlZ6XFSs

Relevance to External Industry?

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Process Safety Overview

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HSE Common Failings?

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Managing Process Safety

Plant

Process

People

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Process Safety Asset Management Lifecycle

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Layers of Protection

Aims of Layers of Protection

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Prevention, Control &

Mitigation of Process Incidents

Emergency Response

Prevention, Prevention, Prevention, Prevention, Control &

Passive Protection

Control & Prevention, Prevention, Prevention, Control &

Active Protection

Safety Shutdown

Basic Process Control

Process Incident

Layers of Protection

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Transferable Tools!HAZOPS!Management of Change

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!HAZOPS! Multidisciplined team! Process split in to sections! Hazards systematically assessed individually and as a

whole! Provides operations risk assessment base

HAZOPS

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The MoC Process

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HAZOP’s – Bulk Emulsion Plant

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Safety Systems and Emergency Training

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Smart Blasting MoC

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!Process Safety Introduction

!Relevance to Other Industries

!Process Safety Overview

!Transferable Tools

!Application

Summary

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