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New York : John Wiley & Sons, Incorporated, 2018

1 online resource (423 pages)

ISBN 9781118795040 (electronic bk.)

ISBN 9781118795071

Print version: Safety), CCPS (Center for Chemical Process Guidelines for Integrating Process Safety into Engineering Projects New York : John Wiley & Sons, Incorporated,c2018 ISBN 9781118795071

Intro -- GUIDELINES FOR INTEGRATING PROCESS SAFETY INTO ENGINEERING PROJECTS -- Contents -- List of Figures -- List of Tables -- Acronyms and Abbreviations -- Glossary -- Acknowledgments -- Files on the Web -- Preface -- 1 INTRODUCTION -- 1.1 Background and Scope -- 1.2 Why Integrating Process Safety is Important -- 1.3 What Type of Projects Are Included? -- 1.4 Project Life Cycle -- 1.5 Relationship to Other Programs -- 1.6 Structure of this Document -- 2 PROJECT MANAGEMENT CONCEPTS AND PRINCIPLES -- 2.1 Common Principles and Structure -- 2.1.1 Statement of Requirements -- 2.1.2 Project Scope -- 2.1.3 Basis of Design -- 2.1.4 Project Budget -- 2.1.5 Project Plan -- 2.1.6 Project Life Cycle -- 2.2 Project Management -- 2.3 Project Governance -- 2.4 Types of Project -- 2.4.1 Greenfield Projects -- 2.4.2 Brownfield Projects -- 2.4.3 Retrofit / Expansion Projects -- 2.4.4 Control System Upgrade Projects -- 2.4.5 Demolition Projects -- 2.4.6 Management of Change Projects -- 2.4.7 Mothballing Projects -- 2.4.8 Re-Commissioning Projects -- 2.4.9 Restarting a Project -- 2.4.10 Post-Incident Projects -- 2.5 Project Organization -- 2.5.1 Pre-Project Team -- 2.5.2 Typical Project Team -- 2.5.3 Unit Based Team -- 2.5.4 Equipment Based Team -- 2.5.5 Site Based Team -- 2.5.6 Small Projects -- 2.5.7 Roles and Responsibilities -- 2.6 Strategies for Implementation -- 2.6.1 Contractor Selection -- 2.6.2 Engineering Only -- 2.6.3 Engineering and Procurement -- 2.6.4 Engineering, Procurement and Construction -- 2.6.5 Operation -- 2.6.6 Contractor Oversight -- 2.7 Risk Management -- 2.8 Project Controls -- 2.8.1 Planning and Progress -- 2.8.2 Estimates, Budgets and Cost Control -- 2.8.3 Reporting -- 2.8.4 Metrics -- 2.8.5 Action Tracking -- 2.8.6 Change Management -- 2.9 Other Considerations -- 2.9.1 Materials Management -- 2.9.2 Quality Management.

11.5.3 Workforce Involvement.

5.2.6 Hazard Identification and Risk Analysis (HIRA) -- 5.2.7 Safety Assessments -- 5.2.8 Re-Evaluate Major Accident Risk -- 5.2.9 Finalize Important Safety Decisions -- 5.2.10 Finalize Basis of Design -- 5.3 Other Engineering Considerations -- 5.3.1 Asset Integrity Management -- 5.3.2 Quality Management -- 5.3.3 Contractor Selection -- 5.3.4 Brownfield Developments -- 5.4 Other Activities -- 5.4.1 EHS and Process Safety Plans -- 5.4.2 Risk Register -- 5.4.3 Action Tracking -- 5.4.4 Change Management -- 5.4.5 Documentation -- 5.4.6 Preparation for Project Execution -- 5.5 Case for Safety -- 5.6 Stage Gate Review -- 5.7 Summary -- 6 DETAILED DESIGN STAGE -- 6.1 Detailed Design -- 6.1.1 Design Hazard Management Process -- 6.1.2 Inherently Safer Design Optimization -- 6.1.3 Site Layout -- 6.1.4 Design Safety Measures -- 6.1.5 Set Performance Standards -- 6.1.6 Hazard Identification and Risk Analysis (HIRA) -- 6.1.7 Safety Assessments -- 6.1.8 Re-Evaluate Major Accident Risk -- 6.1.9 Other Design Reviews -- 6.2 Procurement -- 6.3 Asset Integrity Management -- 6.4 Other Process Safety Activities -- 6.4.1 Case For Safety -- 6.5 Other Project Activities -- 6.5.1 EHS and Process Safety Plans -- 6.5.2 Risk Register -- 6.5.3 Action Tracking -- 6.5.4 Change Management -- 6.5.5 Documentation -- 6.5.6 Constructability -- 6.5.7 Contractor Selection -- 6.6 Preparation for Construction -- 6.7 Preparation for Pre-Commissioning, Commissioning, and Startup -- 6.8 Stage Gate Review -- 6.9 Summary -- 7 CONSTRUCTION -- 7.1 Planning -- 7.2 Pre-Mobilization -- 7.3 Mobilization -- 7.4 Execution -- 7.4.1 Procurement -- 7.4.2 Fabrication -- 7.4.3 Safety Culture -- 7.4.4 Workforce Involvement -- 7.4.5 Stakeholder Outreach -- 7.4.6 Contractor Management -- 7.4.7 Transportation -- 7.4.8 Equipment and Materials Handling -- 7.4.9 Hazard Evaluation -- 7.4.10 Engineering Design.

9.8 Handover -- 9.9 Preparation for Ongoing Operation -- 9.10 Project Close-Out -- 9.10.1 Close Out Report -- 9.10.2 Post-Project Evaluation -- 9.11 Summary -- 10 OPERATION -- 10.1 Process Safety Management System -- 10.1.1 Process Safety Culture -- 10.1.2 Compliance with Standards -- 10.1.3 Process Safety Competency -- 10.1.4 Workforce Involvement -- 10.1.5 Stakeholder Outreach -- 10.1.6 Process Knowledge Management -- 10.1.7 Hazard Identification and Risk Analysis -- 10.1.8 Operating Procedures -- 10.1.9 Safe Work Practices -- 10.1.10 Asset Integrity and Reliability -- 10.1.11 Contractor Management -- 10.1.12 Training and Performance Assurance -- 10.1.13 Management of Change -- 10.1.14 Operational Readiness -- 10.1.15 Conduct of Operations -- 10.1.16 Emergency Management -- 10.1.17 Incident Investigation -- 10.1.18 Measurement and Metrics -- 10.1.19 Auditing -- 10.1.20 Management Review and Continuous Improvement -- 10.1.21 EHS and Process Safety Procedures -- 10.2 Other Project Activities -- 10.2.1 EHS and Process Safety Plans -- 10.2.2 Risk Register -- 10.2.3 Action Tracking -- 10.3 Technical Support -- 10.4 Performance Test Runs -- 10.5 Operation Stage Gate Review -- 10.6 Post-Operational Review -- 10.7 Project Close-Out -- 10.8 Summary -- 11 END OF LIFE -- 11.1 Design for Decommissioning -- 11.2 Planning for Decommissioning -- 11.2.1 Engineering Survey -- 11.2.2 Hazard Evaluation -- 11.2.3 Hazardous Materials -- 11.2.4 Process Safety Plan -- 11.2.5 Utilities -- 11.2.6 Re-Engineering -- 11.3 Decommissioning Procedures -- 11.3.1 Late-Life Operations -- 11.3.2 Cessation of Production -- 11.3.3 Cleaning and Decontamination -- 11.3.4 Mothballed Facilities And Equipment -- 11.4 Deconstruction and Demolition -- 11.4.1 Deconstruction -- 11.4.2 Demolition -- 11.5 Process Safety for Decommissioning -- 11.5.1 Contractor Management -- 11.5.2 Safety Culture.

2.9.3 Lessons Learned -- 2.9.4 Post-Project Close-Out -- 2.10 Stage Gate Reviews -- 3 FRONT END LOADING 1 -- 3.1 Preliminary Hazard Identification -- 3.2 Preliminary Inherently Safer Design Review -- 3.3 Concept Risk Analysis -- 3.4 Other Activities -- 3.4.1 Process Safety and EHS Plan -- 3.4.2 Risk Register -- 3.4.3 Action Tracking -- 3.5 Stage Gate Review -- 3.6 Summary -- 4 FRONT END LOADING 2 -- 4.1 Evaluation of Development Options -- 4.1.1 Hazard Identification -- 4.1.2 Preliminary Inherently Safer Design Review -- 4.1.3 Concept Risk Analysis -- 4.1.4 Selection of the Development Option -- 4.2 Further Definition of the Selected Option -- 4.2.1 Design Hazard Management Process -- 4.2.2 Preliminary Inherently Safer Design (ISD) -- 4.2.3 Hazard Identification and Risk Analysis (HIRA) -- 4.2.4 Engineering Design Regulations, Codes, and Standards -- 4.2.5 Design Philosophies/Strategies -- 4.2.6 Preliminary Facility Siting Study -- 4.2.7 Preliminary Fire and Explosion Analysis -- 4.2.8 Transportation Studies -- 4.2.9 Preliminary Blowdown and Depressurization Study -- 4.2.10 Preliminary Fire & -- Gas Detection Study -- 4.2.11 Preliminary Fire Hazard Analysis -- 4.2.12 Preliminary Firewater Analysis -- 4.2.13 Preliminary Security Vulnerability Analysis -- 4.2.14 Other Engineering Design Considerations -- 4.3 Other Activities -- 4.3.1 EHS and Process Safety Plan -- 4.3.2 Risk Register -- 4.3.3 Action Tracking -- 4.3.4 HIRA Strategy -- 4.3.5 Documentation -- 4.3.6 Stage Gate Review -- 4.4 Summary -- 5 FRONT END LOADING 3 -- 5.1 Evaluation of Development Options -- 5.2 Further Definition of the Selected Option -- 5.2.1 Design Hazard Management Process -- 5.2.2 Inherently Safer Design Optimization -- 5.2.3 Facility Siting and Layout -- 5.2.4 Refine Design Safety Measures -- 5.2.5 Set Performance Standards.

7.4.11 Safe Work Practices -- 7.4.12 Operating, EHS and Process Safety Procedures -- 7.4.13 Training and Competence Assurance -- 7.4.14 Asset Integrity Management -- 7.4.15 Change Management -- 7.4.16 Emergency Response -- 7.4.17 Incident Investigation -- 7.4.18 Auditing -- 7.4.19 Performance Measurement -- 7.4.20 Operations Case for Safety -- 7.4.21 Pre-Commissioning -- 7.4.22 Mechanical Completion -- 7.4.23 Documentation -- 7.5 Other Project Activities -- 7.5.1 EHS and Process Safety Plans -- 7.5.2 Risk Register -- 7.5.3 Action Tracking -- 7.5.4 General Construction Management -- 7.6 De-Mobilization -- 7.7 Preparation for Commissioning and Startup -- 7.8 Final Evaluation and Close-out -- 7.9 Stage Gate Review -- 7.10 Summary -- 8 QUALITY MANAGEMENT -- 8.1 Design/Engineering -- 8.2 Procurement -- 8.3 Fabrication -- 8.4 Receipt -- 8.5 Storage and Retrieval -- 8.6 Construction and Installation -- 8.7 Operation -- 8.8 Documentation -- 8.9 Summary -- 9 COMMISSIONING AND STARTUP -- 9.1 Preparation -- 9.1.1 Planning -- 9.1.2 Safety -- 9.2 Operational Readiness -- 9.2.1 Pre-Startup Stage Gate Review -- 9.2.2 Operational Readiness Review -- 9.2.3 Start-Up Efficiency Review -- 9.3 Commissioning -- 9.3.1 Equipment Testing -- 9.3.2 Commissioning Procedures -- 9.4 Startup -- 9.4.1 Preparation for Startup -- 9.4.2 Calibration of Instruments and Analyzers -- 9.4.3 Startup with Process Chemicals/Fluids -- 9.5 Common Process Safety Elements -- 9.5.1 Hazard Evaluation -- 9.5.2 Safe Work Practices -- 9.5.3 Procedures -- 9.5.4 Training and Competence Assurance -- 9.5.5 Management of Change -- 9.5.6 Incident Investigation -- 9.5.7 Emergency Response -- 9.5.8 Auditing -- 9.5.9 Documentation -- 9.5.10 Performance Measurement -- 9.6 Other Project Activities -- 9.6.1 EHS and Process Safety Plans -- 9.6.2 Risk Register -- 9.6.3 Action Tracking -- 9.7 Performance Test Runs.

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