Safety and Security Review for the Process Industries (eBook)

Front Cover 1
Safety and Security Review for the Process Industries 4
Copyright Page 5
Contents 8
Preface 14
Acknowledgments 16
About the Author 18
1. Purpose 20
2. Scope 24
3. Objective and Description of PHA, What-If, and HAZOP Reviews 26
1. Definition 28
2. Objectives 28
3. Origins of Qualitative Safety Reviews 28
4. Limitations or Disadvantages 29
4.1 Limitations 29
4.1.1 Preliminary Hazard Analysis 29
4.1.2 What-If reviews 29
4.1.3 HAZOP reviews 30
4.2 Advantages 30
4.2.1 Preliminary Hazard Analysis 30
4.2.2 What-If reviews 30
4.2.3 HAZOP reviews 30
4. Adaptation to Security Vulnerability Analysis 32
1. Comparison to Process Hazard Analysis Reviews 33
2. SVA Overall Procedure 33
3. Major Differences Between Security Vulnerability Analyses and Process Hazard Analyses 34
4. Threat Analysis Necessity 34
5. Specialized Reviews—Bow-Tie Analysis, Layers of Protection Analysis, and Safety Integrity Levels 36
1. Bow-Tie Analysis 36
2. Layers of Protection Analysis 37
3. SIL Analysis 40
6. Team Members, Qualifications, and Responsibilities 44
1. Team Members 45
1.1 Minimum team members 45
1.2 Supplemental members 46
2. Team Member Qualifications 47
2.1 Team leader 47
2.2 Scribe 48
2.3 Project manager (project, process, manufacturing, or facility engineer) 48
2.4 Operations representative 48
2.5 Loss prevention or safety representative 48
2.6 Security officer or representative (for SVAs) 48
2.7 Supplemental team member 48
3. Team Responsibilities 49
3.1 Team leader 49
3.2 Scribe 50
3.3 Project manager (project, process, manufacturing, or facility engineer) 50
3.4 Operations representative 51
3.5 Loss prevention or safety representative 51
3.6 Security officer or representative (for SVAs) 51
3.7 Supplemental team member(s) 52
4. Team Dynamics 52
4.1 Leadership influences 52
4.2 Lines of communication 52
4.3 Efficiency factors 53
4.3.1 The number of nodes or areas in the review 53
4.3.2 The completeness of the design versus level of safety review desired 53
4.3.3 The experience of the review team 53
4.3.4 The effectiveness of the team leader 54
4.3.5 The language background of the review team 54
4.3.6 The number of review team members 54
4.3.7 The number of similar or duplicate process vessels or support equipment 54
5. Use of Consultants 54
5.1 Qualifications 55
5.2 Advantages 55
5.3 Disadvantages 56
6. Record of Employee Experience 56
7. Management Support and Responsibilities 58
8. Review Applications for Typical Facilities 60
1. PHA Review Applications 62
2. What-If Review Applications 62
3. HAZOP Review Applications 62
4. SVA Review Applications 64
5. Application During Changes at a Facility 65
9. Review Procedures 66
1. Review Preparation and Setup 67
1.1 Location 67
1.2 Administrative support 67
1.3 Facility documentation 68
1.4 PHA consequence and likelihood data resources 71
1.5 SVA Threat Analysis data resources 72
1.6 Computer hardware and software support 72
1.7 Node identification 73
1.8 SVA area identification 74
2. Review Methodology 74
3. Review Procedure 76
3.1 Review steps 76
3.1.1 PHA and What-If review steps 76
3.1.2 HAZOP review steps 77
3.1.3 SVA review steps 78
3.1.4 Threat Analysis 80
4. Credible Scenarios and Causes 82
5. Possible Causes 84
6. Safeguards 84
7. Likelihood (Probabilities) 85
8. Consequences 85
9. Notetaking 85
10. Helpful Review Suggestions 86
11. Helpful Technical Suggestions 87
11.1 General 87
11.2 HAZOP suggestions 88
11.3 General PHA, What-If, HAZOP, and SVA review suggestions 89
12. Assumptions for the Review Process 91
13. Providing Recommendations 92
13.1 Examples of inadequate versus adequate recommendations 94
13.2 How to rank recommendations 94
14. Quality Audit 95
10. Review Worksheets 98
1. PHA Worksheet 98
2. What-If Worksheet 101
3. HAZOP Worksheet 101
4. SVA Worksheets 105
5. Worksheet Identification 105
11. Report Preparation and Distribution 106
1. Report Stages and Purpose 106
2. Report Preparation and Organization 107
3. Report Distribution 107
3.1 Preliminary reports 108
3.2 Draft reports 109
3.3 Final reports 110
3.4 Addendum reports 110
12. Handling and Resolution of Recommendations 112
1. Ranking and Classifying Recommendations 112
1.1 Recommendation resolution summary 114
2. Objectives of a Safe and Secure Facility Design 114
3. Recommendation Action Plans 115
4. Risk Assessment Studies 115
5. Risk Acceptance Criteria 116
6. Cost–Benefit Analysis 116
13. Schedule and Cost Estimates 118
1. Schedule 118
1.1 Formula to estimate review scheduling 119
1.2 Time bar scheduling and integration with project schedule 120
2. Cost Estimate 121
3. Estimating Formula 121
3.1 Cost of preparation 121
3.2 Cost of review sessions 123
3.3 Cost of report preparations and review 123
3.4 Documentation costs 123
3.5 Hardware, software, and incidental costs 123
4. Example calculation for schedule and cost 124
Appendix A. Typical Company Policy Statement 126
A Safely Managed Company 126
Appendix B. Quality Assurance Audit Checklist 128
Appendix C. Probability, Severity, Risk, and Risk-Acceptance Tables 130
Appendix D. PHA and What-If Checklist Questions 134
Part 1 Piping 134
What-If checklist 134
Part 2 Valves 135
What-If checklist 135
Part 3 Processing Vessels 136
What-If checklist 136
Feed 136
Vessel 136
Vessel piping 136
Fired vessels 137
Vessel external factors 138
Part 4 Tanks 138
What-If checklist 138
Feed 138
Tank 138
Tank piping 139
Tank external factors 139
Part 5 Pumps 139
What-If checklist 139
Part 6 Compressors 140
What-If checklist 140
Part 7 Heat Exchangers 141
What-If checklist 141
Exchanger feed 141
Exchanger 141
Exchanger piping 141
Exchanger external factors 142
Part 8 Reactors 142
What-If checklist 142
Part 9 Columns (Towers) 143
What-If checklist 143
Part 10 Flares 144
What-If checklist 144
Flare piping 144
External factors 144
Part 11 Electrical Equipment 145
What-If checklist 145
Generators 145
Motors 145
Motor control center 145
Switchgear 145
Part 12 Cooling Towers 146
What-If checklist 146
Part 13 Utility Systems 146
What-If checklist 146
Part 14 Human Factors 147
What-If checklist 147
General 147
Operators 148
Equipment 148
Part 15 Global Events 149
What-If checklist 149
Maintenance 149
Sampling 149
Testing 149
Weather 149
Geological events 150
Transportation 150
Human induced 150
Human civil 151
Appendix E. HAZOP Parameters, Deviations, and Possible Causes 152
Parameters, Deviation, and Possible Causes 152
Flow 152
Level 153
Pressure 154
Temperature 155
Part of 156
As well as 156
Other than 157
Viscosity 157
Relief system 157
Corrosion/erosion 157
Service failures 157
Abnormal operation 158
Maintenance/procedures 158
Static 158
Spare equipment 159
Sampling/procedures 159
Time 159
Action 159
Information 159
Sequence 160
Safety systems 160
Global 160
List of Acronyms 162
Glossary 164
Bibliography 170
Index 172