Guidelines for Process Safety Documentation

✍ Scribed by Center for Chemical Process Safety (CCPS)

• Publisher: Wiley-AIChE
• Year: 1995
• Tongue: English
• Leaves: 418
• Category: Library

✦ Synopsis

The process industry has developed integrated process safety management programs to reduce or eliminate incidents and major consequences, such as injury, loss of life, property damage, environmental harm, and business interruption. Good documentation practices are a crucial part of retaining past knowledge and experience, and avoiding relearning old lessons. Following an introduction, which offers examples of how proper documentation might have prevented major explosions and serious incidents, the 21 sections in this book clearly present aims, goals, and methodology in all areas of documentation. The text contains examples of dozens of needed forms, lists of relevant industry organizations, sources for software, references, OSHA regulations, sample plans, and more.

✦ Table of Contents

Guidelines for Process Safety Documentation......Page 1
Front Matter......Page 2
Preface......Page 4
Acronyms......Page 6
Glossary......Page 11
Table of Contents......Page 13
1.1 Process Safety Management Activities the Center for Chemical Process Safety......Page 30
1.2 Benefits of Process Safety Management......Page 31
1.3 Description of Documentation......Page 33
1.4 Organizational and Individual Responsibilities......Page 34
1.6 How to Use This Book......Page 35
1.8 References......Page 36
2.1 Introduction......Page 38
2.1.1 Examples of Incidents Associated with Inadequate Documentation......Page 39
2.2 Goals and Benefits of Documentation......Page 40
2.4 Summary......Page 41
2.5 References......Page 42
3.1.2 Goals and Benefits......Page 43
3.2.2 More Detailed Documentation......Page 44
3.2.3 Responsibility and Accountability......Page 48
3.3.2 Records Revision and Retention......Page 49
3.5 References......Page 50
4.1.2 Goals and Benefits......Page 51
4.2.1 Manual Systems......Page 52
4.2.4 System Selection......Page 53
4.3.1 Documentation of Records Management Accountability and Responsibility......Page 54
4.4.1 Where Maintained......Page 55
4.4.2 Document Control......Page 59
4.4.3 Choice of Media......Page 60
4.4.5 Document Management Systems......Page 61
4.4.6 Fire Protection......Page 62
4.4.7 Environmental Damage Control......Page 63
4.4.8 Security......Page 64
4.4.10 Destruction......Page 65
Appendix 4A: Records Management Resources......Page 66
5.1.2 Goals and Benefits......Page 70
5.2.1 Objectives......Page 71
5.2.2 Sources and Nature of Process Knowledge......Page 72
5.3.1 Process Knowledge Program Documentation......Page 92
5.3.2 Records from Implementing the Process Knowledge Element......Page 94
5.6.1 Inadequate Investigation and Documentation of Chemicals Prior to Process Application......Page 95
5.7 References......Page 96
Appendix 5A: Example of Process Knowledge File Index......Page 98
6.1.1 Introduction......Page 100
6.2.1 Objectives......Page 101
6.2.2 Method 1: Safety Reviews......Page 102
6.2.3 Method 2: Checklist Analysis (CL)......Page 103
6.2.4 Method 3: Relative Ranking Analysis......Page 104
6.2.5 Method 4: Preliminary Hazard Analysis......Page 105
6.2.6 Method 5: What-If Analysis (WI)......Page 106
6.2.7 Method 6: What-If/Checklist Analysis (WICL)......Page 107
6.2.8 Method 7: Hazard and Operability Study (HAZOP)......Page 111
6.2.10 Method 9: Fault Tree Analysis (FTA)......Page 115
6.2.11 Method 10: Event Tree Analysis (ETA)......Page 119
6.2.12 Method 11: Cause-Consequence Analysis (CCA)......Page 120
6.2.13 Method 12: Human Factors Analysis (HFA)......Page 122
6.3.1 PHA Program Documentation......Page 123
6.3.2 Documentation of PHA Results......Page 127
6.3.3 Resolution of PHA Recommendations......Page 129
6.4.2 Media and Methods......Page 130
6.5 Auditing......Page 131
6.6.1 Runaway Reaction in a Polymerization Reactor......Page 132
7.1.1 Introduction......Page 134
7.1.2 Goals and Benefits......Page 135
7.2.1 Objectives......Page 136
7.3.1 CPQRA Program Documentation......Page 137
7.3.2 Documentation of CPQRA Results......Page 138
7.3.3 Resolution of CPQRA Recommendations......Page 140
7.6 References......Page 141
Appendix 7A: Graphical Presentation of CPQRA Results......Page 142
Appendix 7B: Documentation of Supporting Data......Page 144
Appendix 7C: Other Aspects of CPQRA Documentation......Page 146
8.1.2 Goals and Benefits......Page 149
8.2.2 Process Equipment Integrity as Part of Process Safety Management......Page 150
8.3.2 Records from Implementing Process Equipment Integrity Element......Page 151
8.4.2 Where Maintained......Page 156
8.6.1 Inadequate Documentation of Equipment Integrity Requirements and Management of Change Procedures......Page 157
8.7 References......Page 158
Appendix 8A: Example of Documentation Requirements for Mechanical Equipment......Page 159
Appendix 8B: Example of Documentation Requirements for Electrical Equipment......Page 164
Appendix 8C: Example of Documentation Requirements for Instrumentation Equipment.......Page 171
Appendix 8D: Example of Documentation Requirements for Safety Systems Equipment......Page 175
9.1.2 Goals and Benefits......Page 178
9.2.2 Human Factors in the Life Cycle of a Process Facility......Page 179
9.3.1 Human Factors Program Documentation......Page 181
9.3.2 Documentation of HFA Results......Page 182
9.3.3 Resolution of HFA Recommendations......Page 183
9.6.1 Types of Human Error......Page 184
9.7 References......Page 186
Appendix 9A: Typical Technical Documentation of HFA......Page 187
10.1.2 Goals and Benefits......Page 201
10.2.2 Management of Change as Part of Process Safety Management......Page 202
10.3.1 MOC Program Documentation......Page 203
10.3.2 Records from Implementing the MOC Element......Page 206
10.4.3 Responsibility and Accountability......Page 211
10.5 Auditing......Page 212
10.7 References......Page 213
11.2 Description of Operating Procedures......Page 214
11.2.2 Key Elements and Preparation of Operating Procedures......Page 215
11.3.1 Operating Procedures Program Documentation......Page 217
11.3.2 Records from Implementing the Operating Procedures Element......Page 219
11.4.2 Where Are Records Maintained?......Page 220
11.4.5 Access Control......Page 221
11.5 Auditing......Page 222
11.6.2 Abnormal Operations......Page 223
11.7 References......Page 224
12.1.2 Goals and Benefits......Page 225
12.2.1 Types of Training Methods......Page 226
12.2.3 Refresher Training......Page 227
12.2.4 Training Evaluation......Page 228
12.2.5 Training Module Guidelines......Page 229
12.3.2 Records from Implementing the Training Element......Page 232
12.4.2 Media and Methods......Page 233
12.5 Auditing......Page 234
12.6 References......Page 235
Appendix 12B: OSHA Regulations......Page 236
13.1.2 Goals and Benefits......Page 239
13.2.2 Planning for Emergency Response......Page 240
13.3.1 Emergency Response Program Documentation......Page 243
13.3.2 Records from Implementing an Emergency Response Program......Page 244
13.4.1 Where Are Records Maintained?......Page 246
13.5 Auditing......Page 247
13.7 References......Page 248
Planning Element A: Introduction......Page 249
Planning Element B: Emergency Assistance Telephone Roster......Page 253
Planning Element C: Response Functions......Page 254
Planning Element D: Containment and Cleanup......Page 262
Planning Element E: Documentation and Investigative Follow-Up......Page 263
Planning Element F: Procedures for Testing and Updating Plan......Page 264
Planning Element H: References......Page 265
14.1.2 Goals and Benefits......Page 266
14.2.2 Types of Audits......Page 267
14.2.3 Audit Methodology References......Page 268
14.3.1 Audit Program Documentation......Page 269
14.3.2 Records from Implementing the Auditing Element......Page 271
14.4.1 Storage Locations......Page 272
14.5 References......Page 273
15.1.2 Goals and Benefits......Page 274
15.2.2 Conducting Incident Investigations......Page 275
15.3.2 Documentation of Incident Investigation Results......Page 278
15.3.3 Resolution of Incident Report Recommendations......Page 279
15.4.2 Records Control......Page 280
15.6.2 Proper Follow-Up Prevents Recurrent Equipment Damage......Page 285
15.7 References......Page 286
16.1.2 Goals and Benefits......Page 287
16.2.1 Objectives......Page 288
16.2.2 Differentiation among Standards, Codes, and Regulations......Page 289
16.2.3 Sources of Standards, Codes, and Regulations......Page 290
16.4 Records Management......Page 291
16.4.2 Records Procurement......Page 292
16.4.4 Records Retention and Purge Procedures......Page 294
16.5 Auditing......Page 295
Appendix 16A: Organizations in the United States that Write Codes, Standards, and Regulations......Page 296
17.1.2 Goals and Benefits......Page 302
17.2.2 Owner Responsibilities......Page 303
17.2.3 Contractor Responsibilities......Page 304
17.3.1 Owner's Program Documentation......Page 306
17.3.3 Records from Addressing Contractor Issues......Page 307
17.4.2 Retention/Purge Schedule......Page 308
17.5.1 Auditing by the Contractor......Page 309
17.7 References......Page 310
18.1.1 Introduction......Page 312
18.2.1 Objectives......Page 313
18.3.1 Permit-to-Work Systems Program Documentation......Page 314
18.4.3 What Media Should Be Used?......Page 317
18.5 Auditing......Page 318
18.6.3 Application of Permit-to-Work System Not Comprehensive......Page 319
Appendix 18A: Typical Rules and Responsibilities for Permit-to-Work Systems......Page 320
Appendix 18B: Hot-Work Permit......Page 322
Appendix 18C: General Permit-to-Work......Page 323
Appendix 18D: Lockout/Tagout Permit......Page 326
Appendix 18F: Confined Space Entry Permit......Page 329
Appendix 18G: Other Permit Systems......Page 330
19.1.1 Introduction......Page 337
19.2.2 Control Software Applications......Page 338
19.2.3 Software Life Cycle......Page 339
19.3.1 Control Software Documentation Program......Page 340
19.3.2 Definition Stage Records......Page 341
19.3.3 Design Stage Records......Page 346
19.3.4 Implementation Stage Records......Page 347
19.3.6 Installation and Checkout Stage Records......Page 348
19.3.7 Operations and Maintenance Stage Records......Page 349
19.4.3 Management of Change......Page 350
19.4.4 Configuration Management......Page 351
19.5 Auditing......Page 352
19.6.2 Inadequate Test and Documentation of Control Software......Page 353
Appendix 19A: Quality Control of Software Documentation......Page 354
20.1.1 Introduction......Page 359
20.2.1 What Is a Document?......Page 360
20.2.2 Overall Document Flow......Page 361
20.2.3 Company Generated Documents......Page 362
20.2.5 Working Documents......Page 363
20.2.6 Reference Documents......Page 365
20.2.7 Archival Documents or Records......Page 366
20.2.8 Quantities of Documents......Page 367
20.3 Description of Document Life Cycle......Page 368
20.4 Detailed Example......Page 372
20.5 References......Page 374
21.1.1 Introduction......Page 375
21.1.2 Goals and Benefits......Page 376
21.2.1 Electronic Information Management......Page 377
21.2.3 Types of Emerging Technologies......Page 379
21.3 Emerging Technologies Applied to Documentation......Page 382
21.4.1 Considerations on the Use of Emerging Technologies......Page 384
21.4.2 General Issues for Implementation......Page 385
21.4.3 Implementation for Specific Elements of PSM......Page 386
21.5 Vision for the Future......Page 390
21.6 References......Page 391
A......Page 392
C......Page 393
D......Page 397
E......Page 399
F......Page 401
H......Page 402
I......Page 403
L......Page 405
O......Page 406
P......Page 407
R......Page 412
S......Page 415
T......Page 416
W......Page 418

✦ Subjects

Безопасность жизнедеятельности и охрана труда;Радиационная и химическая защита;