Index

Abnormal situation management, 532 Accident, 588 Air, 177 ALARP see As Low as Reasonably Practical American Chemistry Council, 295 American National Standards Institute, 297 American Petroleum Institute, 294 American Society of Mechanical Engineers, 296 Analogies, 629 Area classication, 306 As Low as Reasonably Practical, 39 Assessments expert, 717 management, 720 template, 725 Asset integrity overview, 301 OSHA PSM regulation, 781 Audits budget, 704 ndings, 712 rst impressions, 702 formal, 694 forms, 705 goals, 703 host company, 701 ineffective, 66 insurance, 697 kick-off meeting, 707 OSHA PSM regulation, 693, 795 personnel, 698 planning, 702 reasons for, 695 report, 710 schedule, 704 standards, 697 unannounced, 713 voluntary, 696 Auditor attributes, 699 internal, 698 interviews, 708 outside, 698 regulators, 804 team, 699 Availability, 353 Bathtub curve, 359 Bayes Theorem, 364 BBS see Behavior-Based Safety Behavior-Based Safety, 380 Big crew change, 60 Blame avoidance of, 583 types of, 584 BLEVE see Boiling Liquid Expanding Vapor Explosion Boiling liquid expanding vapor explosion, 204 Bow-tie method, 30 CCPS see Center for Chemical Process Safety Center for Chemical Process Safety, 296, 657 Certication see Testing, 540 CFR see Code of Federal Regulations Change administrative, 667 covert, 663 emergency, 666 organizational, 667 overt, 663 temporary, 664 types of, 661 Checklists, 143 Clients/customers, 803, 824 Client/attorney privilege, 839 Closed Circuit Television, 619 Code of Federal Regulations, 734 Codes, 52, 732 Commissioning, 416, 817 Common cause events, 169, 245, 637 Common hazards, 161 Communications meetings, 825 presentations, 824 Compressors, 319 Conned space entry, 392 Consequence analysis matrix, 42 nature of, 28, 192 reduction, 86 safety, 192 Consultants, 821 Contractors nature of, 73 OSHA PSM regulation, 777 selection of, 74 training, 77 Control systems see Instrumentation Copyright, 833

845

846 Index

Culture developing, 67 elements of, 48 historical development, 51 nature of, 47 DCS see Distributed Control Systems Decommissioning, 122 Demolition, 122 Discrete event analysis, 258 Distributed Control Systems, 180 Drugs/Alcohol, 584, 595 Economies of Scale, 33 Effectiveness, 354 EHS see Health, Safety and Environmental Electrical equipment, 307 Emergency planning and response human response, 544 levels of emergency, 546 OSHA PSM regulation, 791 other regulations, 792 planning, 549 safeguard, 271 Emergency Response Planning Guidelines, 209 Emergency Showers, 412 Employee participation overview, 69 OSHA PSM regulation, 761 Emulators see Simulators Energy control car seals, 387 electrical isolation, 385 isolation techniques, 383 lockout/tagout, 386 padlocks, 387 positive isolation, 382 removal of the hazard, 382 tags, 388 temporary plugs, 383 Engineering information block ow diagram, 284, 363 piping & instrument diagram, 285 OSHA PSM regulation, 763 process ow diagram, 285 reliability block diagrams, 360 Environmental, 23, 194 Environmental Protection Agency, 735 EPA see Environmental Protection Agency ERPG see Emergency Response Planning Guidelines ETA see Event Tree Analysis Events, 6 base, 227 house, 227 intermediate, 226 top, 226

Event Tree Analysis combining with fault trees, 255 quantication, 255 Examples, 7 Explosions deagration/detonation, 203 dust, 204 physical, 202 vapor cloud, 202 Exponential distribution, 358 Eyewashes see Emergency showers Failure modes, 355 Failure modes & effects analysis, 151 Failure rates, 356, 366 Failure rate data, 276, 364 Fault-nding, 583 Fault Tree Analysis cut sets, 232 development, 228 events, 226 gates, 220 generic reliability tree, 251 generic safety tree, 250 nature of, 218, 252 qualitative, 253 Findings nature of, 104, 142 non-ndings, 110 Fires detection, 553 ghting, 557 reproong, 308 ammability, 200 ammable range, 195 ignition sources, 198 triangle, 223 zones, 557 Fireghting media rewater, 558 other media, 562 Fire extinguishers, 564 Flame arrestors, 332 Flares, 334 FMEA see Failure modes & effects analysis Frequency analysis, 37, 216 matrix, 44 FTA see Fault Tree Analysis Fusible Links, 555 Gates (fault tree) and gate, 222 or gate, 220 voting gate, 224 Go Team, 592

Index 847

Hazard identication, 94 Hazard and operability method node selection, 133 process guidewords, 136 safeguards, 140 Hazards chemicals, 213 compressed gas, 176 elimination, 86 experience based, 85 identication, 79, 83 management, 82 nature of, 27 substitution, 86 Hazards analysis benets/limitations, 125 charge letter, 89 documentation, 92 indexing methods, 157 leader, 96 logistics, 90 organization of, 87 OSHA PSM regulation, 766 report, 108 scribe, 101 special types of, 122 team, 95 time required, 93 HAZID see Hazard Identication HAZOP see Hazard and Operability Method Health, 24, 193 Health, Safety and Environmental, 23 Heat Detectors, 555 Heat Exchangers air-cooled, 321 boilers, 323 cooling towers, 322 shell and tube, 321 Hoses, 171, 184 Hot Taps, 375 Hot work permits, 391 HSE see Health, Safety and Environmental Human Error errors of intent, 188 xation, 189 mistakes, 189 nature of, 632 slips, 189 Ice, 175 IDLH see Immediately Dangerous to Life and Health Ignition Temperature, 196 Immediately Dangerous to Life and Health, 210 Importance ranking, 217, 244, 262 Important few, 242

Incidents denition of, 587 publicizing, 576 open communication, 576 potential incident, 588589 reporting, 585 safety as a cause of, 585 Incident databases, 651 Incident Investigation categorization, 630 communicating, 586 fault tree analysis, 634 follow-up, 691 information gathering, 591 initial, 589 interviews, 609 limitations of, 575 lying to investigators, 584 management levels, 577 investigation process, 589 OSHA PSM regulation, 789 photographs, 618 reasons for, 575 recommendations, 637 regulations, 578 report, 592, 595, 637 supervision, 577 team, 590, 594 timeline, 592, 619 trust, 580, 614 witness interviews, 613 Independence, 38 Information, 277 Information security chain of custody, 93, 646 OSHA PSM regulation, 798 record retention, 647 trade secrets, 798 Inspection frequency, 344 programs, 343 risk-based, 345 Instrumentation alarms, 335 interlocks, 336 trips, 336 Interface hazards analysis, 158 Internal combustion engines, 339 International Organization for Standardization, 297 Investigators lead, 603 outside, 601 Job Safe Practices, 458 JSPs see Job Safe Practices

848 Index

Ladders, 378 Lagging indicators, 714 Layer of Protection Analysis independent protection layer, 273 method, 271 Layout see Siting Leading Indicators, 716 Levels of Protection, 631 Lightning, 200 Likelihood, 28, 38, 87 Litigation Support, 66, 834 LOPA see Layer of Protection Analysis Maintainability, 355 Maintenance repair, 397 condition-based, 397 organization, 399 procedures, 432, 457 scheduled, 398 reliability centered, 398 Major Hazards Screening, 94 Managers, 84 Management incident investigation, 577 trust, 585 Malicious Acts, 584 Management of Change benets of, 656 builders, 683 committee, 688 coordinator, 682 denition of, 657 evaluation of, 680 form, 674 initiator, 671 in-kind/not-in-kind, 659 informal, 668 justication, 676 OSHA PSM regulation, 786 process, 670 reviewers, 678, 684 software, 684 sponsor, 672 Markov Models, 261 Material Safety Data Sheets, 280 Materials of Construction, 287 MAWP see Maximum Allowable Working Pressure Maximum allowable working pressure, 310 Minerals Management Service, 750 Minimum ow bypass, 317 MMS see Minerals Management Service MOC see Management of Change Monte Carlo Simulation, 260 MSDS see Material Safety Data Sheets

National Fire Protection Association, 293 Naturally Occurring Radioactive Materials, 377 Near Miss/Hit, 588 Non-process operations, 409 NORM see Naturally Occurring Radioactive Materials Occupational Safety, 20 Occupational Safety & Health Administration, 736, 742 Ofce safety, 409 Operating manual design of, 469 instructions, 478 modules, 473 writing team, 489 Operating Procedures authorization block, 480 batch, 451 content development, 484 denition of, 430 emergency, 552 failure to follow, 584 links to information, 482 maintaining, 501 OSHA PSM regulation, 770 overview, 426 quick assessment, 436 shut down, 446 software analogy, 457 standard, 452 start-up, 444 steady-state, 443 temporary, 451 users, 438 Operational excellence, 2 Operational integrity management, 1 Operational readiness overview, 418 OSHA PSM regulation, 779 OSHA see Occupational Safety & Health Administration P&ID see Engineering Information: piping & instrument diagram Pareto Principle, 216, 349 Passive re protection, 201 Personal protective equipment clothing, 407 eye protection, 408 re ghting, 565 foot protection, 407 hand protection, 406 head protection, 405 respiratory protection, 408 Pigging, 176 Piping

Index 849

overview, 181, 324 unplugging, 375 Risk PPE see Personal Protective Equipment Prestartup Safety Review see Operational Readiness Probit, 208 Process hazards, 161 Process safety management denition of, 22 elements of, 760 fundamentals of, 11 goal-driven regulations, 731 holistic, 21 metrics, 18, 808 OSHA standard, 737 overview, 3 non-prescriptive, 16 plan, 810 program organization, 804 rule-based regulations, 729 trends, 22 Process safety management regulation audits, 795 contractors, 777 employee participation, 761 emergency planning and response, 791 hot work, 785 incident investigation, 789 operating procedures, 770 management of change, 786 mechanical integrity, 781 prestartup safety review, 779 process hazards analysis, 766 process safety information, 763 training, 774 trade secrets, 798 Project manager, 84 Projects hazards analysis, 159 phases of, 814 PSSR see Operational Readiness Publishing, 522 Pumps, 315 Pyrophorics, 200 Quality Management ISO 9000/140001, 25 six sigma, 26 Quantication limits to, 266 RAGAGEP see Recognized and Generally Accepted Good Engineering Practice RAM see Reliability Random numbers, 260 Randomness, 38

Recognized and Generally Accepted Good Engineering Practice, 41, 300 Recommendations, 104 Regulations (Federal) citations, 740 entry process, 739 general duty clause, 734 Health and Safety Executive (UK), 23 OSHA inspections, 737 process, 733 tenth amendment, 735 United States, 733 Regulations (State) Delaware, 749 Nevada, 749 Toxic Catastrophe Prevention Act (New Jersey), 749 Regulations (International), 757 Reliability benets of, 348 denition of, 352 redundancy, 361 Relief valves block valves below, 329 function, 185, 327 shared, 329 thermal, 330 Revalidation hazards analysis, 123 Reviews, 717 Report writing date format, 830 draft report, 825 language, 827 minimalist writing, 504, 828 multiple languages, 526 writing style, 503, 506, 828 Risk acceptable, 38 comprehension time, 36 de minimis, 41 equation, 35 indexing methods, 42 matrices, 42, 45 nature of, 26 presence of persons, 31 quantication of, 37 rank, 85, 142 subjective nature, 33 Risk Register, 106 Risk management professional education, 818 knowledge of past events, 819 personal attributes, 818 technical knowledge, 818 Risk Management Program (EPA) covered chemicals, 745

850 Index

Risk Management Program (EPA) (Continued ) projects, 813 rule, 743 tiering, 745 worst case release, 748 RMP see Risk Management Program Root Cause Analysis failure to identify, 67 levels of, 627 types of, 581, 592, 628 denitions of, 582 Rupture disks, 331 Safe limits emergency limits, 14 management of change, 690 mixing range, 13 operating limits, 14 Safe work practices housekeeping, 372 machinery, 377 minimizing contact with air, 373 OSHA PSM regulation, 785 spills and overows, 374 tie-ins, 399 Safety case regime assessment, 756 elements of, 752 structure of, 753 Safety committees, 70 Safety diamond, 283 Safety Instrumented Systems, 270, 337 Safety meetings, 77 Safeguards emergency response, 271 mechanical, 270 nature of, 87 normal operations, 268 passive, 270 procedural, 269 safety instrumented systems, 270 Security call checklists, 571 sabotage, 585 security vulnerability analysis, 570 theft, 568 Signs, 403 Simulators, 537 SIS see Safety Instrumented Systems Siting blocks, 302 buildings, 305, 341 equipment layout, 303 piping and valves, 304 roads, 302

Smoke detectors, 555 Spontaneous combustion, 197 Stakeholder involvement, 69, 72 Stairways, 378 Standards incident investigation, 578 industry, 288, 697 internal, 697 Start-Up, 416, 817 Static electricity, 199 Steam, 174 Sustainability, 23 Tanks, 314 Testing, 540 Titanic, 36, 57 Toxic gases effects of, 206 exposure limits, 208 models, 205 Training budget, 536 elements of, 530 emergencies, 551 initial/basic, 531 matrix, 535 OSHA PSM regulation, 774 procedures, 533 refresher, 533 TRIZ, 157 Troubleshooting, 448, 545 Unimportant many, 242 Utilities failures, 247 hazards of, 169 layout, 303 Valves, 184, 324 Vessels effect of temperature, 311 nature of, 310 pressure tests, 312 Warning ags, 54 Water, 172 What-If Method, 144 What-If/Checklist Method, 151 Why trees, 633 Witnesses to fact, 836 expert, 836 Work permits, 389 Workers compensation, 52