2-CCPS中国安全领导力和管理培训之操作程序

1Copyright©2011CenterforChemicalProcessSafetyoftheAmericanInstituteofChemicalEngineersOperationsOperatingProceduresWrittendocumentthatprovidesthefollowing:ThestepsneededtoperformataskTheorderinwhichthosestepsaretobeperformed(ifimportant)AnyuniquewarningsorcautionsassociatedwithaparticularstepPurposeofOperatingProcedures2Copyright©2011CenterforChemicalProcessSafetyoftheAmericanInstituteofChemicalEngineersWhereYouNeedOperatingProceduresOperatingproceduresshouldaddressthefollowingscenariosfortheproductionunit…...andwherecomplexityand/orcriticalitywarrant,thesamescenariosasaboveforindividualpiecesofequipment-e.g.compressors,reactors,etc)3Copyright©2011CenterforChemicalProcessSafetyoftheAmericanInstituteofChemicalEngineersWhyIsItImportant?Withoutwrittenoperatingprocedures,afacilitycanhavenoassurancethattheintendedproceduresandmethodsareperformedinsamemannerandsamesequenceby:eachdifferentoperatoreachtimebysameoperator4Copyright©2011CenterforChemicalProcessSafetyoftheAmericanInstituteofChemicalEngineers•Proceduresmustbeconciseandwithoutambiguity•Informationintendedforeducationonchemistry,generalhazards,whytasksareperformedinacertainorderetc.shouldbeplacedintrainingdocumentsContentofProcedures5Copyright©2011CenterforChemicalProcessSafetyoftheAmericanInstituteofChemicalEngineersProceduresAreNOTTrainingDocumentsAllproceduresarenotofsamelevelofcriticality/importanceConsideranairliner•Take-offandLandingProcedures•SequenceforRe-StartofIn-flightEntertainmentSystem•GuidelinesforStorageofOversizePassengerBagsRiskRankingofProcedures6Copyright©2011CenterforChemicalProcessSafetyoftheAmericanInstituteofChemicalEngineersWhenProcedureis….HighconsequenceofdeviationHighcomplexityLow-ModerateconsequenceLow-ModeratecomplexityNegligibleconsequenceLowcomplexityTierProceduresbyRiskRanking7Copyright©2011CenterforChemicalProcessSafetyoftheAmericanInstituteofChemicalEngineersUse....Checklistformat.In-handwhenperformingtask.Stepsinitialled.Writtenformat,butrequiredin-handwhenperformingtaskWrittenformat.PlaceinproceduremanualforreferenceonlyCertificationofProcedures-When8CertificationshouldbedonebeforeprocedureisusedforfirsttimeRecertifyafteranymodification,and/orafteranestablishedtimeperiodCopyright©2011CenterforChemicalProcessSafetyoftheAmericanInstituteofChemicalEngineersCertificationofProcedures9Certificationshouldbedonebyfieldobservationthattheprocedurecanbefollowed….•inthesequenceprovided•withoutneedforsteps/actionsnotprovidedintheprocedureCopyright©2011CenterforChemicalProcessSafetyoftheAmericanInstituteofChemicalEngineersPortNealIA-199410Copyright©2011CenterforChemicalProcessSafetyoftheAmericanInstituteofChemicalEngineersWhatHappened•ExplosioninNH4NO3plantinneutralizerandrundownvesselsasaresultofacidicconditionsandhightemperatures(200psigsteamforsparging)•4Fatalities,18injured•Releaseof5700tofNH3and25,000galHNO3Copyright©2011CenterforChemicalProcessSafetyoftheAmericanInstituteofChemicalEngineersContributingCauses•Lackofwrittenoperatingprocedures•LackoftrainingonnewDCSsystem•NoPHAconducted•PoormechanicalintegrityprogramCopyright©2011CenterforChemicalProcessSafetyoftheAmericanInstituteofChemicalEngineersDiscussionQuestion•Howis“Correctness“ofaprocedurecertifiedinyourfacility?Isitadequate?13Copyright©2011CenterforChemicalProcessSafetyoftheAmericanInstituteofChemicalEngineersManageRiskTrainingAndPerformanceAssuranceCopyright©2011CenterforChemicalProcessSafetyoftheAmericanInstituteofChemicalEngineers15Copyright©2011CenterforChemicalProcessSafetyoftheAmericanInstituteofChemicalEngineersOperationsTrainingandPerformanceAssuranceTraining/PerformanceAssurance•TrainingInstructioninjobandtaskrequirements,methods,andhazardsifnotdoneasinstructed•PerformanceAssurance(Certification)Themeansbywhichworkersdemonstratethattheyunderstoodandretainedthetraining,andcanapplyitcorrectlyinreal-timejobsituations16Copyright©2011CenterforChemicalProcessSafetyoftheAmericanInstituteofChemicalEngineersWhyIsItImportant?17Copyright©2011CenterforChemicalProcessSafetyoftheAmericanInstituteofChemicalEngineersTrainingandPerformanceAssuranceistheonlymeansbywhichafacilitycanbecertainthatanindividual….….understandsthesafeandexpectedprocedureforperformingatask….understandstheconsequencesofdeviationfromtheexpectedprocedure….isphysicallyandmentallycapableofperformingthetaskinthefieldconsistentwiththetrainingFeyzin,France-196618Copyright©2011CenterforChemicalProcessSafetyoftheAmericanInstituteofChemicalEngineersWhatHappened•MajorexplosionsandBLEVEsatLPGrefinery•18fatalities,81injured•Releaseoccurredwhenoperatorwasdrainingwaterfrombottomofasphere•IgnitionbyautomobileonnearbymotorwayCopyright©2011CenterforChemicalProcessSafetyoftheAmericanInstituteofChemicalEngineersWhatHappened•Samplesfrombottomofsphereroutinelytakensobottomhadtobedrainedpriortosampling•Bottomoftankhadtwo2-inchplugvalveswitha¾-inchbleedvalvebetween•Drainlineheatedbysteamtracingbeneathinsulation•Procedurecalledforopeningvalveclosesttovesselandthencrackingopenthebleedvalveandadjustdrawoffrate•Operator