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This is the Mary Kay OConner PSM symp. in 2009 for improvement of PHA speed and quality by introduction of simple tech.
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Process Hazard Analysis: Study Enhancement
Keith V. Farrell, MS ChE
PSM Coordinator
INVISTA, Orange Plant
10/27/2009 1
Keith V. Farrell10/27/2009 2
Beginning Thoughts
The Three Laws of TechnologyThe Three Laws of Technology
By Arthur C. Clark
• When an engineer states that something is possible, he is almost certainly RIGHT. When he states that something is impossible, he is very probably WRONG.
• Any sufficiently advanced technology is indistinguishable from magic.
Keith V. Farrell10/27/2009 3
Study Objectives
• Federal Requirements
• Companies Requirements
• Tools
• Training
• “Bringing all Together”
• Cost and Savings
Keith V. Farrell10/27/2009 4
Federal Requirements
• OSHA CFR Title 29 §1910.119
– Process Safety Management of Highly Hazardous Chemicals
• EPA CFR Title 40 Part 68
– Chemical Accident Prevention Provisions
Keith V. Farrell10/27/2009 5
Company Requirements
• Accuracy and Precision
• Compliance
• Speed
Keith V. Farrell10/27/2009 6
Accuracy and Precision
• Right Recommendations
• Vague Recommendations
• Constrictive Recommendations
• Wrong Recommendations
Keith V. Farrell10/27/2009 7
Speed
• TIME IS MONEY!!!!
• Too Quick of a Pace for the Study
– Team Fails by Being Rushed
– Missed Consequences
• Too Slow of a Pace for the Study
– Team Fails by Tiring of Thinking
– Missed Consequences
– Unnecessary Consequences (Whines)
Keith V. Farrell10/27/2009 8
Tools
• Willing People
• Deep Knowledge
• Accessible Information
• Archiving and Accessing Captured Information for Study
• Equipment
• EIS
Keith V. Farrell10/27/2009 9
Tools
• People, Knowledge, Information, Computer Programs, Archiving Information, Access to Information
• Typical for All PHAs
Keith V. Farrell10/27/2009 10
Tools: Equipment
• Displaying Information
– Eye strain
– Comfort
• Markups of P&IDs
– To Keep the Team on Same “Page”
– Verbal Directions of Nodes
– Not Quick
• Derailing the Thought Train
Keith V. Farrell10/27/2009 11
Tools: Equipment, cont.
•Monitors for each Team Member & Space remaining for P&IDs
– Same Page Issue
– Quick Editing
– Comfortable
10/27/2009Keith V. Farrell
12
Tools: Equipment, cont.
•Document Camera to Project Drawings
– Use Basic Marked Drawings
– Lower Eye Strain
– Faster Information Recognition
– Visual Data preferred
10/27/2009Keith V. Farrell
13
EIS
Electronic Information Systems (EIS)
• What
• Where
• When
• How
Keith V. Farrell10/27/2009 14
EIS: Defined.
• Databases
• Information Availability
• Benefits
Keith V. Farrell10/27/2009 15
EIS: Databases
• PSI necessary for PHA
– PSI
– Alarms/ SIS
– SOLs
– PSV
– Process Control Points
– Process Information Points
– Procedures
Keith V. Farrell10/27/2009 16
EIS
• Proper Form of Database
– Accessibility
– User Friendly
– Updateable
– Protectable
Keith V. Farrell10/27/2009 17
WHAT FORM OF DATABASE?
• Software Needs Questions
– Stable
– Quick
– Ease of Use
– Expandable
– Software Life-span
Keith V. Farrell10/27/2009 18
Accessibility and User Friendly
• Questions to ask
– Who needs access
– What level of access
– Any training necessary
– Who will fix problems
– Who will maintain information
Keith V. Farrell10/27/2009 19
Expandable and Software Life-span
• What will be your PSI needs in the Future
• What software will be there at that time
Keith V. Farrell10/27/2009 20
Cost Analysis
• Equipment
• Software
• Training for Leaders
• Savings!!!!!!!
Keith V. Farrell10/27/2009 21
Equipment
• Seven Monitors @ $150 each
– Two – Operators
– Three– Engineers
– Two – Other Skill Sets
• One Document Camera @ $2000
• Other Minor Equipment @ $300
Keith V. Farrell10/27/2009 22
Software
• PHA Software (Current)
• Adobe Writer @$650
(Based on the assumption you have a computer and associated operational software)
Keith V. Farrell10/27/2009 23
Total Cost
• Equipment = $3350
• Software = $650
• Total = $3850
Keith V. Farrell10/27/2009 24
Training for Leaders
Necessary Training
•Basic Leader Development (In House?)
•Basic Instructor Development (In House?)
•Negotiating Development (In House?)
Items to consider
•Basic Interview Development
•Basic Speakers Development
Keith V. Farrell10/27/2009 25
Savings!!!!!!!
• Time for Initial Studies
– Normal; 5 to 8 weeks
– With Enhancements; 3 to 4 weeks
• Using one Operator & two Engineers; combined cost $270/hr
• Time Savings ~$11,300 per study
Keith V. Farrell10/27/2009 26
Savings, cont.
• Time for Revalidation Studies
– Normal; 2 to 4 weeks
– Enhanced; 1 to 8 study days
• Using one Operator & two Engineers; combined cost $270/hr
• Time Savings ~ $11,300 for each study
Keith V. Farrell10/27/2009 27
The Bottom Line
• Hardware and Software Total = $3350
• Savings per study = ~ $11,300
• Net Saving for the first Study = $7,450
Keith V. Farrell10/27/2009 28
Last Comment
Keith V. Farrell10/27/2009 29
DesiredDesiredResultsResults
PSIPSI
PH
AP
HA
Changes
Changes
THANKS
•Mary Kay O’Connor Process Safety Center
•Dr. M. Sam Mannan
•INVISTAKeith V. Farrell
10/27/2009 30
A Few Questions????
Questions
Questions
Questions
Questions
Questions
Keith V. Farrell10/27/2009 31