Guidelines for Managing Abnormal Situations

The book discusses why management of abnormal situations is important to process safety. The book provides guidance on practical steps to avoid or mitigate an accident or incident before it escalates into a more dangerous and costly issues which can include downtime, lost production, equipment damage, injuries, and external/ environmental damage. Through the use of case studies the book illustrates the impact these deviant occurrences can have on operating facilities.
 
Management principles that can be established before an issue occurs are presented while case studies are used to illustrate the impact that an abnormal situation can have on an operating facility. The impact of plant design are detailed, with separate focus points on new plant design and retrofits to existing plants. A section on writing plant procedures and plant policies so that they incorporate the principles of managing abnormal situations is also included.
 
Training content is provided on how to manage deviant situations, with guidance on presenting the information to specific target populations, such as front-line operators, operations managers, plant engineers, and process safety engineers. Readers are also shown tools that are currently available for recognizing and responding to abnormal situations, and actions that process safety engineers can use during Hazard Identification and Risk Analysis (HIRA).

List of contents

Table of Contents v
 
List of Figures xi
 
List of Tables xiii
 
List of Example Incidents xv
 
Acronyms and Abbreviations xvii
 
Glossary xxi
 
Acknowledgments xxxi
 
Preface xxxv
 
Dedication xxxvi
 
1 Introduction 1
 
1.1 Purpose and Scope of the Book 1
 
1.2 What Are Abnormal Situations? 2
 
1.3 The Business Case for Managing Abnormal Situations 4
 
1.4 Content and Organization of the Book 5
 
2 Process Safety and Management of Abnormal Situations 9
 
2.1 Impact on Process Safety 9
 
2.2 The Case for Positive Management of Abnormal Situations 11
 
2.3 Adverse Outcomes of Abnormal Situations 13
 
2.4 Importance of Training for Abnormal Situations 22
 
2.5 Safety Culture and the Management of Abnormal Situations 23
 
3 Abnormal Situations and Key Relevance to Process Plant Operations 27
 
3.1 Focus Areas for Abnormal Situation Management 27
 
3.1.1 ASM Research Areas 27
 
3.1.2 Additional Focus Areas 30
 
3.2 Abnormal Situations Affecting Process Plant Operations 32
 
3.2.1 Process Control Systems -the First Line of Defense 40
 
3.2.2 Frontline Operators 44
 
3.3 Management of Abnormal Situations and Links to Risk Based Process Safety 48
 
3.3.1 Commitment to Process Safety 50
 
3.3.2 Understand Hazards and Risk 50
 
3.3.3 Manage Risk 50
 
3.3.4 Learn from Experience 51
 
3.3.5 Additional RBPS Elements Related to Management of Abnormal Situations 52
 
3.4 Procedures and Operating Modes for Managing Abnormal Situations 53
 
3.4.1 General Principles for Procedure Development 53
 
3.4.2 Operating Modes 58
 
3.4.3 Types of Material Being Processed 78
 
4 Education for Managing Abnormal Situations 85
 
4.1 Educating the Trainer 85
 
4.2 Primary Target Populations for Training 86
 
4.2.1 Front-line Operators 87
 
4.2.2 Operations Management 89
 
4.2.3 Plant Engineers/Technicians 90
 
4.2.4 Process Safety Engineers 91
 
4.2.5 Design Engineers 91
 
4.2.6 Environmental Health, Safety and Security (EHSS) Personnel 100
 
4.2.7 Technical Experts 100
 
4.2.8 Other Parties 102
 
4.3 Guidance for Organizing and Structuring Training 102
 
4.3.1 Organization of Training 102
 
4.3.2 Structure of Training Topics 103
 
4.3.3 Skills and Competencies of Trainers 106
 
4.4 Summary 106
 
5 Tools and Methods for Managing Abnormal Situations 107
 
5.1 Tools and Methods for Control of Abnormal Situations 108
 
5.2 Predictive Hazard Identification 112
 
5.2.1 Hazard Recognition for Abnormal Situations 113
 
5.2.2 HIRA Approach to Hazard Prediction 113
 
5.3 Process Control Systems 115
 
5.3.1 Process Trend Monitoring 117
 
5.3.2 Alarm Management 119
 
5.3.3 Big Data 122
 
5.3.4 Advanced Diagnostics and Artificial Intelligence 123
 
5.4 Policies and Administrative Procedures 124
 
5.4.1 Expectations of Policies and Administrative Procedures 126
 
5.4.2 The Relationship of Policies to Abnormal Situation Management 126
 
5.4.3 Process Metrics 129
 
5.5 Operating Procedures 130
 
5.5.1 Standard Operating Procedures 131
 
5.5.2 Emergency Procedures 132
 
5.5.3 Transient Operation Procedures 133
 
5.5.4 Preparing Written Procedures 134
 
5.6 Training and Drills 135
 
5.7 Ergonomics and Other Human Factors 139
 
5.7.1 HMI (Human Machine Interface) System 140

About the author

The Center for Chemical Process Safety (CCPS) has been the world leader in developing and disseminating information on process safety management and technology since 1985. The CCPS, an industry technology alliance of the American Institute of Chemical Engineers (AIChE), has published over 100 books in its process safety guidelines and process safety concepts series, and over 30 training modules through its Safety in Chemical Engineering Education (SAChE) series. CCPS is supported by the contributions and voluntary participation of more than 200 companies globally.

Summary

The book discusses why management of abnormal situations is important to process safety. The book provides guidance on practical steps to avoid or mitigate an accident or incident before it escalates into a more dangerous and costly issues which can include downtime, lost production, equipment damage, injuries, and external/ environmental damage. Through the use of case studies the book illustrates the impact these deviant occurrences can have on operating facilities.

Management principles that can be established before an issue occurs are presented while case studies are used to illustrate the impact that an abnormal situation can have on an operating facility. The impact of plant design are detailed, with separate focus points on new plant design and retrofits to existing plants. A section on writing plant procedures and plant policies so that they incorporate the principles of managing abnormal situations is also included.

Training content is provided on how to manage deviant situations, with guidance on presenting the information to specific target populations, such as front-line operators, operations managers, plant engineers, and process safety engineers. Readers are also shown tools that are currently available for recognizing and responding to abnormal situations, and actions that process safety engineers can use during Hazard Identification and Risk Analysis (HIRA).

Product details

• Authors: CCPS, CCPS (Center for Chemical Process Safety), Center for Chemical Process Safety (Ccps, Center for Chemical Process Safety (CCPS)
• Publisher: Wiley, John and Sons Ltd
• Languages: English
• Product format: Hardback
• Released: 31.10.2022
• EAN: 9781119862871
• ISBN: 978-1-119-86287-1
• No. of pages: 272
• Subjects: Natural sciences, medicine, IT, technology > Chemistry; Chemie, Maschinenbau, Arbeitssicherheit, Verfahrenstechnik, chemistry, Chemical Engineering, Mechanical Engineering, chemische Verfahrenstechnik, Chemical and Environmental Health and Safety, Arbeitssicherheit u. Umweltschutz i. d. Chemie, Allg. Maschinenbau, Chemische Verfahrenstechnik / Theorie, Planung u. Management, Theory, Planning & Management