Process, Power and Marine Division Design Safety into Your Plant Mary Kay O’Conner Process Safety Symposium Frank Joop Global Business Development Intergraph Process, Power & Marine

Be Pro-active – “SAFETY FIRST”

Safety is at the Forefront

Was this your plant…………….

The Basics  Risk Reduction –Instrument are a well accepted risk reduction system –Safety for personnel, facility and environment  Contributors to an accident –Course –Process deviation –What is released to the atmosphere

Risk Reduction Increasing Risk Process RiskTolerable RiskResidual Risk Necessary Risk Reduction Actual Risk Reduction (ALARP) ProcessDesignBPCSAlarmsReliefSIS

Tolerable Risk

The Standards  ISA S84.01 and IEC  Framework for the design  Key steps are: –Process design –HAZOP and Risk analysis –Determine protection layers –Define Safety Integrity Level (SIL) –Define SIS –Specification of SIS –Design –Operating procedures –Commissioning –Modification coupled back to the process design

Risk Assessment What if ChecklistWhat if/ Checklist HAZOPFMECAFTA Method Smaller system For repeatable systems For proven designs For larger and more complex systems For any type or size system Plus Fast and simple Standardized approach Good and fast method Very thorough Very thorough, with diagrams Minus Not very thorough No new analysis components Need experienced personnel Very time consuming More for individuals rather then a group approach which means less input from experience

HAZOP’s – What, Why and How?  The best, most rigorous method for hazard assessment  Team of 5 – 8 experienced engineers, operators  Usually after the design / change is complete  Impacts time TO market and time IN market Hazard Identification Likelihood vs. Severity Risk reduction

Process Safety Information Systems Design Control Maintenance Finance  Safety

Process Safety is Mission Critical Law  License to operate Cost  Injury, plant damage  Abnormal upsets Image  Staff  Community  Marketplace

HAZOP’s – What, Why and How? DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION  HAZOP = Hazard and Operability Studies  Study of the possibility of deviation from the design intent  HAZOP Fundamentals: –Deviation –Course  Key words are: –Flow, Temperature, Pressure, Level, Separate (settle, filter, centrifuge), Composition, React Mix, Reduce (grind, crush, etc.), Absorb, Corrode Erode  Operational words –Isolate, Drain, Vent, Purge, Inspect, Maintain, Start-up, Shutdown  Secondary Key Words –No, Less, More, Reverse, Also, Other, Fluctuation, Early, Late

HAZOP’s – What, Why and How? DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION No, Flow Strainer Blockage Pump cavitations Wrong mixing Pressure measurement At pump Inspection of filter Add instr. Verifying each system

 Process Design  Instrument design  Piping layout  Material ordering  HAZOP –Found error –Design change ($$) –Change order for material/equipment ($$$$$) HAZOP’s late in the schedule

DEVIATION CAUSE CONSEQUENCE SAFEGUARDS ACTION No, Flow Strainer Blockage Pump cavitations Wrong mixing Pressure measurement At pump Inspection of filter Add instr. Impact / Follow on Effect: - DCS Configuration - DCS HMI (Graphics) - Alarm Management - Asset Management - Instrumentation Design - Procurement Changes - Vendor Communications - Piping Changes - Material Changes - Construction Planning - Commissioning - Spare Parts Loading - Documentation - Etc... Multiple by thousands of potential “Safe-guards” HAZOP’s late in the schedule

HAZOP’s – Earlier in the schedule  Process Design  Make HAZOP part of design process early on  Instrument design  Piping layout  Material ordering  HAZOP (final) –No errors –No Design change –No Change order for material/equipment  Reduced design and CAPEX risks

SmartPlant Process Safety enables to design safety into your plant and reduces the operational risks.  Design = EPC  Operational = OO The Solution

SPPS Process Safety information Hazop study Knowledge base Knowledge from experts, captured once only Structured database Full, auditable record Comprehensive Consistent - Up to 50% time & cost reduction P&IDs Lessons learned

Plant safety information today Hazop study Maintenance Plant Modification Operation Lack of safety data impacts Plant safety knowledge

The Solution Equipment Models in SmartPlant Process Safety  Knowledge about the behaviour of process equipment is essential for hazard identification.  Each equipment type in SPPS has a “Model”. –Describes behaviour, failure modes and hazards. –Connects to other equipment through ports. –Models collected into a “Unit Model Library”.  “Instances” of these equipment models are used in the P&IDs which SPPS analyses.

The Solution Flow Modelling… P in P out Q out Q in T out T in P out + + P in + + etc… + – + +– noQ out noQ in Consequence: dry running Centrifugal pump:

The Solution Plant Modelling…

The Solution Equipment Models

The Solution Fault-consequence Lists…

The Solution Fault-consequence detail

The Solution Fault-Consequence Assessment

MoC workflow P&IDs Plant Safety database from SPPS and Hazop study Existing plant Proposed modification /new batch sheet Modify P&IDs Run SPPS to find hazards Engineering approval Safety approval Permit to work Compare and Hazop new cause- consequences Final approval

The Solution Comparing before and after Hazops

The Solution Any more F/C in this Node & deviation? Brainstorming

HAZOP’s w/ SP Process Safety Traditional HAZOP Study SP Process Safety HAZOP Study û Manually divide P&ID’s / Plant into “nodes” to study and mark-up P&ID’s û Manually prepare “node” work- sheet û Focus on individual node and deviation at a time û Manually work to identify fault- Consequence both inside and outside the node û Manually identify and document safe- guards / instrumentation û Assign actions and manually communicate them to respective disciplines û Manually document study for future reference / audits ü Automatically create “nodes” using intelligent data / rules from SmartPlant P&ID ü Semi-Automatic preparation of “node” worksheet, interactive navigation and selection from P&ID database ü Interactive visual aid to P&ID for brain storming activities ü Automatic recommendations of Safe-Guards ü Electronic and collaborative assignment of actions for respective disciplines ü Automatic -notification of actions, including action management functions ü Automatically generate HAZOP reports / results ü History management / comparison reports

Process Safety Integration Vision... CORPORATE SAFETY MEMORY Data & Document Management ‘eEngineering Integration Hub’ TEF SP- PID SP3D SPI SPEL TEF BROWSER TEF HAZOPS ACCIDENT DATA MoC SECURITY ACCIDENT INVESTIGATION CALCULATIONS HUMAN FACTORS

Business Results Achieved Hazard Identification Automation Risk Assessment Action Management Data Handover Early Hazard Elimination  50% time & cost reduction  Project schedule reduction  Consistent, thorough, Auditable  Re-usable, comparable Action validation Unified record  Faster re- hazops  Better MoC  Lessons learned  Safety of acquisitions Build corporate safety memory (CSM)  Capture knowledge of experts once and re-use always Check designs Using CSM  Better design  Make changes before limited, costly  Shorter Hazop studies  Better action management Visual aid to improve brainstorming

Summary  Full, auditable, consistent Hazops record  Reduced time, cost and tedium  Early design checking enables change before becomes costly, limited  Knowledge capture and use –Company’s experts’ experience –lessons learned  Hazop study results - living data –Supporting MoC –Accessible information

Process, Power and Marine Division Integrating the Engineering Enterprise…