Safe Change Management

Key focus areas in Chemical Process industry : 

Key focus areas in Chemical Process industry Change and Equipment Management are key ELEMENTS in Process Safety System. Some of the World’s “News splash incidents” have involved Change Management as focal point Equipment Management is no less important Change Management should follow appropriate Process Hazard Analysis CCPS is an excellent reference for proper application of Process Hazard Evaluation Techniques

Hazard Evaluation TechniquesGuideline for Hazard Evaluation Procedure –Buy CCPS Book : 

Hazard Evaluation TechniquesGuideline for Hazard Evaluation Procedure –Buy CCPS Book Typical Techniques mentioned Safety review Checklists Relative Ranking Preliminary Hazard Analysis What –If , What-If checklist HAZOP FMEA FTA ETA CCA HRA

Change Management--Essentials : 

Change Management--Essentials Change need driver Criteria for Change : SHE, IDLH, Life threatening, Insurance, Legal, Statutory items should get priority attention Change initiation procedure publication Prescribing Change processing steps Determining Change review Team composition Validating Change acceptance criteria Sign off protocol in Change approval checklist

Preceding Activity. : 

Preceding Activity. Change Planning should focus on PEME Change organising should list -Preceding/Succeeding activity Change control, MOC,Conformance to Codes, Fabrication qualification , Inspection types-Source, Incoming,On-site, Material Spec, OEM Spec sheets,Deviation control/Approval are key aspects before Change implementation Change validation should be tested by PDCA prior to Change confirmation as Permanent Change benefit evaluation is necessary

Succeeding Activities : 

Succeeding Activities Change revision Confirmation SOP Revision. OSEP Review Re-training Re-certification of Trained personnel P.M. List Update Isometrics, P & ID, related Doc Update Spares Identification, Inventory stipulation

Contd.. : 

Contd.. Payout tracking Archiving database

Equipment Management—Book keeping : 

Equipment Management—Book keeping MOC Fabrication details, Related drawings, Isometrics Flanges, Gaskets, Nuts, Bolts, Piping, Bends, Elbows, Fittings, Insulation-- Specifications Sheet FLP/IP/FRLS/HR /ZH/--DCS, PLC, SCADA Built-in Safety devices/features List of Codes/Standards adopted MTO Installation qualification Process/Operational qualification including HAZOP study Final qualification—ID, Asset entry, Insurance

Documentation/Maintenance : 

Documentation/Maintenance Deliverables Statutory SOP O &M Manuals OEM-Recommended Spares Spares Management kardex P.M. List/NDT Schedule Work instructions History card MTBF Charts

Performance Support Needs : 

Performance Support Needs List of Lubricants Supply Sources—Qualifications of Suppliers –Criteria AMC/Warranty Trade supports—Electrical, Instrumentation, EHS,Engg Performance trending Run Log Inspection-Sensorial, Instrumentation (Speed, Vibration, Fatigue, Noise, Heat and such) NDT-Methodology, Monitoring Tools

Breakdown-Impact review aids : 

Breakdown-Impact review aids Incident log and reports Macro Interruptions Micro interruptions RCA, Component reliability analysis Recovery Time Impact analysis—Economic/Customer impact Insurance Cover—Fire/Allied, Machinery Break down, LOP, Natural/Security perils, Human contributory

Conclusion : 

Conclusion Change involves thinking holistically Change may necessitate downtime Interruption due to incidents can affect safety of personnel and Business economics. Each change review should be situation specific. General references cannot displace internal Multi-disciplinary review and validation. Yet changes can become necessary to continually improve Safety, Health & Environment

Abbreviations List -AL : 

Abbreviations List -AL AMC Annual Maintenance Contract CCA Cause Consequence Analysis CCPS Centre for Chemical Process Safety DCS Distributed Control System EHS Environment, Health & Safety FLP Flameproof FMEA Failure Mode and Effects Analysis FRLS Fire Resistant Low Smoke HAZOP Hazard Operability HR Heat Resistant HRA Human Reliability Analysis IDLH Immediately Dangerous to Life & Health IP Ingress Protection LOP Loss of Profit

AL : 

AL MOC Material of Construction MTBF Mean Time Between Failure MTO Material Transfer Order NDT Non Destructive Testing O & M Operation & Maintenance OEM Original Equipment Manufacturer OSEP On Site Emergency Plan P & ID Piping & Instrumentation Diagram PDCA Plan Develop Check and Act PEME People, Environment, Materials, Equipment PHA Process Hazard Analysis PLC Programme Logic Controller PM Preventive Maintenance

AL : 

AL R & D Research & Development RCA Root Cause Analysis SCADA Supervisory Control and Data Acquisition SHE Safety, Health & Environment SOP Standard Operating Procedure ZH Zero Halogen Source credits: Publications, Experiences, Professional contributions, Interactions with Chemical Industry,OEMs.