1、1 Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers Operations Operating Procedures Written document that provides the following:The steps needed to perform a task The order in which those steps are to be performed(if important)Any unique warnings or c
2、autions associated with a particular step Purpose of Operating Procedures 2 Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers Where You Need Operating Procedures Operating procedures should address the following scenarios for the production unit .and w
3、here complexity and/or criticality warrant,the same scenarios as above for individual pieces of equipment-pressors,reactors,etc)3 Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers Why Is It Important?Without written operating procedures,a facility can
4、have no assurance that the intended procedures and methods are performed in same manner and same sequence by:each different operator each time by same operator 4 Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers Procedures must be concise and without a
5、mbiguity Information intended for education on chemistry,general hazards,why tasks are performed in a certain order etc.should be placed in training documents Content of Procedures 5 Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers Procedures Are NOT
6、Training Documents All procedures are not of same level of criticality/importance Consider an airliner Take-off and Landing Procedures Sequence for Re-Start of In-flight Entertainment System Guidelines for Storage of Oversize Passenger Bags Risk Ranking of Procedures 6 Copyright 2011 Center for Chem
7、ical Process Safety of the American Institute of Chemical Engineers When Procedure is.High consequence of deviation High complexity Low-Moderate consequence Low-Moderate complexity Negligible consequence Low complexity Tier Procedures by Risk Ranking 7 Copyright 2011 Center for Chemical Process Safe
8、ty of the American Institute of Chemical Engineers Use.Checklist format.In-hand when performing task.Steps initialled.Written format,but required in-hand when performing task Written format.Place in procedure manual for reference only Certification of Procedures-When 8 Certification should be done b
9、efore procedure is used for first time Recertify after any modification,and/or after an established time period Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers Certification of Procedures 9 Certification should be done by field observation that the p
10、rocedure can be followed.in the sequence provided without need for steps/actions not provided in the procedure Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers Port Neal IA-1994 10 Copyright 2011 Center for Chemical Process Safety of the American Inst
11、itute of Chemical Engineers What Happened Explosion in NH4NO3 plant in neutralizer and rundown vessels as a result of acidic conditions and high temperatures(200 psig steam for sparging)4 Fatalities,18 injured Release of 5700t of NH3 and 25,000gal HNO3 Copyright 2011 Center for Chemical Process Safe
12、ty of the American Institute of Chemical Engineers Contributing Causes Lack of written operating procedures Lack of training on new DCS system No PHA conducted Poor mechanical integrity program Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers Discussi
13、on Question How is Correctness of a procedure certified in your facility?Is it adequate?13 Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers Manage Risk Training And Performance Assurance Copyright 2011 Center for Chemical Process Safety of the America
14、n Institute of Chemical Engineers 15 Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers Operations Training and Performance Assurance Training/Performance Assurance Training Instruction in job and task requirements,methods,and hazards if not done as ins
15、tructed Performance Assurance(Certification)The means by which workers demonstrate that they understood and retained the training,and can apply it correctly in real-time job situations 16 Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers Why Is It Impo
16、rtant?17 Copyright 2011 Center for Chemical Process Safety of the American Institute of Chemical Engineers Training and Performance Assurance is the only means by which a facility can be certain that an individual.understands the safe and expected procedure for performing a task.understands the consequences of deviation from the expected procedure.is physically and mentally capable of performing the task in the field consistent with the training Feyzin,France-1966 18 Copyright 2011 Center for Ch
