2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential

nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operational Safety
Operational Safety
Engineering Design Seminar
October 2006
Scott Wozniak
UOP Process Technology & Equipment
Health, Safety & Environmental Manager
Engineering Design Seminar
October 2006
Scott Wozniak
UOP Process Technology & Equipment
Health, Safety & Environmental Manager
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Objectives
Objectives
Review the Elements of Operational
Safety
How Operational Safety Impacts an
Engineers Activities
Design,
Operation,
Maintenance, and
Modification
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operational Safety Overview
Operational Safety Overview
Explosions & Fires
Flixborough, UK (1974)
Seveso, Italy (1976)
Bhopal, India (1984)
Mexico City, Mexico (1984)
Piper Alpha, North Sea (1988)
Concerns by Many Countries
Regulations or Standards in Australia, Germany, India, UK,
USA, and so on.
Concerns by Bankers and Insurers
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Major Process Hazard Event
Major Process Hazard Event
A Major Process Hazard Event is defined as
a release of a toxic or hazardous substance,
a fire,
an explosion,
a sudden release of energy or
other process-related incident,
which could result in life- threatening injury or fatality
employees,
visitors,
contractors or
persons outside the site or
cause environmental damage.
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Major Process Hazard Event
Major Process Hazard Event
A potential MPHE can be virtually
eliminated with a good, well-
maintained
Operational Safety Program
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Engineering Impact
Engineering Impact
As an Engineer...
How are you involved in
Operational Safety activities?
Directly Involved
Provide Input
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operational Safety Elements
Operational Safety Elements
1. Operational Hazards
2. Technology & Safety Information
3. Engineering Design Reviews
4. Process Hazard Analyses
5. Procedures
6. Mechanical Integrity
7. Training
8. Modifications
9. Pre-Startup Safety Reviews
10. Decommissioning/Recommissioning
11. Process Incident Investigations
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operational Safety Elements
Operational Safety Elements
1. Operational Hazards - direct
2. Technology & Safety Information - direct
3. Engineering Design Reviews - direct
4. Process Hazard Analyses - direct
5. Procedures input to HR or Operations
6. Mechanical Integrity input to Maintenance
7. Training input to HR or Operations
8. Modifications - direct
9. Pre-Startup Safety Reviews input to safety
10. Decommissioning/Recommissioning - direct
11. Process Incident Investigations - input to safety
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operational Safety Elements
Operational Safety Elements
Balance of this session will be
A brief review of each of the Operational
Safety elements,
The role that you play as technical experts
in your plants Operational Safety Program
Discussion of any questions you may
have regarding OpSafety Programs.
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operational Safety
Operational Safety
Element #1
Element #1
Operational Hazards
Operational Hazards
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operational Hazards
Operational Hazards
Who knows how to
Identify
Operational
Operational
Hazards
Hazards
better than a
Process
Process
Engineer?
Engineer?
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operational Hazards
Operational Hazards
Identifying Potential Operational
Hazards Feeds Into..
New Designs
Modifications to Existing Plants/Units
Operating Procedures
Mechanical Integrity Programs
Training
Are you starting to notice a trend?
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operational Hazards
Operational Hazards
Sample Checklist
Operational Hazards
Operational Hazards
With
With
Major Process Hazard Event
Major Process Hazard Event
Potential
Potential
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operational Safety
Operational Safety
Element #2
Element #2
Technology & Safety
Technology & Safety
Information
Information
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Technology & Safety Information
Technology & Safety Information
Technical Basis of the Operation*
Design specifications
Vendor information, including Licensor Technology Manuals
Emergency Characterization, Control
& Mitigation*
Design Standards, Codes and References*
Exposure Information
Hazards of Materials
Material Safety Data Sheets or Safety Sheets
Glossary of Terms for Better Understanding the Sheets
*Must be Documented
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Technology & Safety Information
Technology & Safety Information
Technical Basis of the Operation*
Design specifications
Vendor information, including Licensor Technology Manuals
Emergency Characterization, Control
& Mitigation*
Design Standards, Codes and References*
Exposure Information
Hazards of Materials
Material Safety Data Sheets or Safety Sheets
Glossary of Terms for Better Understanding the Sheets
*Must be Documented
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Technology & Safety Information
Technology & Safety Information
Sample Checklist
Safety Factors Checklist
Safety Factors Checklist
For
For
Material Safety Data Sheets
Material Safety Data Sheets
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operational Safety
Operational Safety
Element #3
Element #3
Engineering Design Reviews
Engineering Design Reviews
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Engineering Design Reviews
Engineering Design Reviews
What can You do during Design Reviews to
Improve the Safety of Your Operations?
Assess Adequacy of Controls and Safety
Systems
Assess Compliance with Government
Legislation and Regulations
Include Inherently Safer Thinking
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Engineering Design Reviews
Engineering Design Reviews
What can You do during Design Reviews to
Improve the Safety of Your Operations?
Assess Adequacy of Controls and Safety
Systems
Assess Compliance with Government
Legislation and Regulations
Include Inherently Safer Thinking
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Engineering Design Reviews
Engineering Design Reviews
What can You do during Design Reviews to
Improve the Safety of Your Operations?
Assess Adequacy of Controls and Safety
Systems
Assess Compliance with Government
Legislation and Regulations
Include Inherent Safety
Can you define an inherently safer design??
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Engineering Design Reviews
Engineering Design Reviews
An Inherently Safer Design is one that
avoids hazards instead of controlling them
by adding protective equipment or
is safe by its very nature and not because
equipment has been added to make it
safer.
(1)
(1)
Kletz, T.A., Process Plants: A Handbook for Inherently Safer Design, (Philadelphia, PA,
USA: Taylor & Francis, 1998), Chapter 1
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Inherent Safety Strategies
Inherent Safety Strategies
Minimize
minimizing the amount of hazardous material that is in use
Substitute
substituting less hazardous materials and processes wherever possible
Moderate
moderating the process conditions of the hazardous materials
Simplify
simplifying the equipment and processes that are used
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Inherent Safety Strategies
Inherent Safety Strategies
Substitution
Moderation
Simplification
Minimization
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Inherent Safety Strategies
Inherent Safety Strategies
Substitution
Using Hypochlorite tablets instead of Chlorine
Using Solid Catalyst instead of HF Acid or H
2
SO
4
for Alkylation
Minimization
Reducing Reactor size
Reducing Feed/Product Storage
Reducing the amount of hazardous chemical
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Inherent Safety Strategies
Inherent Safety Strategies
Moderation
Using Aqueous NH
3
instead of Anhydrous NH
3
Injecting diluted H
2
instead of Pure H
2
Designing for lower pressure or lower temperature
Simplification
Cooling with an exchanger rather a vacuum system
Using more piping welds and fewer flanges
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operational Safety
Operational Safety
Element #4
Element #4
Process Hazard Analysis
Process Hazard Analysis
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Process Hazard Analysis
Process Hazard Analysis
Why Conduct a PHA?
Improve Safety
Identify Potential Process Risks
Identify Critical Equipment
Improve Operations
Improve Procedures
Enhances Training
Understand Impacts of One Section of the Process on
Another Section
Minimize Unplanned Emergency Shutdowns (costly) Minimize Unplanned Emergency Shutdowns (costly)
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Process Hazard Analysis
Process Hazard Analysis
Why Conduct a PHA?
Improve Safety
Identify Potential Process Risks
Identify Critical Equipment
Improve Operations
Improve Procedures
Enhances Training
Understand Impacts of One Section of the Process on
Another Section
Minimize Unplanned Emergency Shutdowns (costly) Minimize Unplanned Emergency Shutdowns (costly)
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Process Hazard Analysis
Process Hazard Analysis
Types of Hazard Analyses
Hazard & Operability (HAZOP) Study Hazard & Operability (HAZOP) Study
What If? Analysis What If? Analysis
Checklist
Failure Modes & Effects Analysis
Fault Tree Analysis
Process HSE Review
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Process Hazard Analysis
Process Hazard Analysis
Types of Hazard Analyses
Hazard & Operability (HAZOP) Study Hazard & Operability (HAZOP) Study for Process
What If? Analysis What If? Analysis for Process
Checklist
Failure Modes & Effects Analysis Failure Modes & Effects Analysis for Equipment
Fault Tree Analysis
Process HSE Review
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Process Hazard Analysis
Process Hazard Analysis
Sample Worksheets
Hazards & Operability (HAZOP)
Hazards & Operability (HAZOP)
Study
Study
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Process Hazard Analysis
Process Hazard Analysis
Types of Hazard Analyses
Hazard & Operability (HAZOP) Study Hazard & Operability (HAZOP) Study
What If? Analysis What If? Analysis
Checklist
Failure Modes & Effects Analysis
Fault Tree Analysis
Process HSE Review
Additional Enhancements
Facility Siting
Human Factors Industry Guidelines
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Process Hazard Analysis
Process Hazard Analysis
Sample Checklists
Facility Siting Review
Facility Siting Review
Human Factors in
Human Factors in
Process Operations
Process Operations
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Process Hazard Analysis
Process Hazard Analysis
When to Conduct PHAs
New Process
Modifications to a Process
Periodic Revalidation (every 5-7 years) [Safety]
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Is this a
New Process
Unit?
Is this an
Existing
Process
Unit?
Was a PHA
Previously
Conducted?
PHA
Revalidate the
PHA
Communicate
to Affected
Employees
Report Status of
Resolution to
Facility Management
Document
the Closure
Are
Recommendations
Resolved?
N Y Y
N
N
Y
Y N
Process Hazard Analysis
Process Hazard Analysis
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Process Hazard Analysis
Process Hazard Analysis
Who Should Participate?
Process Expert
Engineer
Process Specialist
Operations Expert
Operators
Supervisors
Maintenance Expert
PHA Expert
Instrument Expert
Others
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Process Hazard Analysis
Process Hazard Analysis
Who Should Participate?
Process Expert
Engineer
Process Specialist
Operations Expert
Operators
Supervisors
Maintenance Expert
PHA Expert
Instrument Expert
Others
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Process Hazard Analysis
Process Hazard Analysis
What Steps should be
followed for Identified
Improvement
Recommendations?
Implement the actions
Document the study and
the actions taken
Share the results
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operational Safety
Operational Safety
Element #5
Element #5
Operating & Maintenance
Operating & Maintenance
Procedures
Procedures
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operating & Maintenance
Operating & Maintenance
Procedures
Procedures
Are you involved in Developing
Operating Procedures?
Types of Operating Procedures
Startup
Normal Operations
Shutdown
Emergency Scenarios
Who Periodically Reviews Your
Sites Operating Procedures?
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operating & Maintenance
Operating & Maintenance
Procedures
Procedures
Procedure Step (Prior)
From the extractor platform,
start the extractor drive and
set the variable drive to the
speed setting desired.
[No reference to proper settings.]
Not suggested
Procedure Step (Current)
Action
Start the Extractor drive and
adjust the variable speed
drive to the speed setting
desired.
Detail
Use the drive controls located
at the Extractor Platform.
Refer to the Standard
Operating Instructions for
initial speed setting.
Suggested
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operating & Maintenance
Operating & Maintenance
Procedures
Procedures
Sample Written Procedures
Startup of an Extractor (Poor)
Startup of an Extractor (Poor)
Startup of an Extractor
Startup of an Extractor
(Recommended)
(Recommended)
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operating & Maintenance
Operating & Maintenance
Procedures
Procedures
Are You Involved in Developing
Maintenance Procedures?
Who Provides the Equipment
Specifications?
Types of Maintenance Procedures
Notice to Operations (when work starts)
Lockout and Tag Out of Power Sources
Confined Space Entry
Equipment Repair/Replacement
Notice to Operations (when work is finished)
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operating & Maintenance
Operating & Maintenance
Procedures
Procedures
Are You Involved in Developing
Maintenance Procedures?
Who Provides the Equipment
Specifications?
Types of Maintenance Procedures
Notice to Operations (when work starts)
Lockout and Tag Out of Power Sources
Confined Space Entry
Equipment Repair/Replacement
Notice to Operations (when work is finished)
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operating & Maintenance
Operating & Maintenance
Procedures
Procedures
Emergency Response Procedure
How are Plant Personnel Warned?
Is There a Plant Emergency Response Team?
Are Outside Emergency Responders Involved?
How Often is the Emergency Procedure Tested?
Who Helps Operators Understand How to Make
Their Units Safe During an Emergency?
Who Designates Types of Emergencies?
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operating & Maintenance
Operating & Maintenance
Procedures
Procedures
Emergency Response Procedure
How are Plant Personnel Warned?
Is There a Plant Emergency Response Team?
Are Outside Emergency Responders Involved?
How Often is the Emergency Procedure Tested?
Who Helps Operators Understand How to Make
Their Units Safe During an Emergency?
Who Designates Types of Emergencies?
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operational Safety
Operational Safety
Element #6
Element #6
Mechanical Integrity Program
Mechanical Integrity Program
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Mechanical Integrity Program
Mechanical Integrity Program
Definition of Mechanical Integrity
Those aspects of production, maintenance, technical,
quality and purchasing which ensure that there is a
system in place for the proper design, construction, on-
going integrity and reliability of the process equipment
over the entire lifecycle of the process.
Mechanical Integrity Program includes
Identifying Critical Equipment
Conducting Predictive Maintenance
Establishing Type and Frequency of Equipment
Testing
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Mechanical Integrity Program
Mechanical Integrity Program
Definition of Mechanical Integrity
Those aspects of production, maintenance, technical,
quality and purchasing which ensure that there is a
system in place for the proper design, construction, on-
going integrity and reliability of the process equipment
over the entire lifecycle of the process.
Mechanical Integrity Program includes
Identifying Critical Equipment
Conducting Predictive Maintenance
Establishing Type and Frequency of Equipment
Testing
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Mechanical Integrity Program
Mechanical Integrity Program
Definition of Mechanical Integrity
Those aspects of production, maintenance, technical,
quality and purchasing which ensure that there is a
system in place for the proper design, construction, on-
going integrity and reliability of the process equipment
over the entire lifecycle of the process.
Mechanical Integrity Program includes
Identify Critical Equipment
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Mechanical Integrity Program
Mechanical Integrity Program
Critical Equipment
Process equipment, which if failure occurs, could result
in a Major Process Hazard Event
pressure vessels
storage vessels/tanks
piping
valves
relief and vent systems
emergency shutdown systems
controls
pumps
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Mechanical Integrity Program
Mechanical Integrity Program
Definition of Mechanical Integrity
Those aspects of production, maintenance, technical,
quality and purchasing which ensure that there is a
system in place for the proper design, construction, on-
going integrity and reliability of the process equipment
over the entire lifecycle of the process.
Mechanical Integrity Program includes
Identify Critical Equipment
Conduct Predictive Maintenance
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Mechanical Integrity Program
Mechanical Integrity Program
Predictive Maintenance
Equipment Equipment Failure Failure Detection
Category Types Mode Cause Method
Rotating
Machinery
Pumps,
Motors
Premature
Bearing Loss
Excessive
Forces
Vibration &
Lube Analysis
Compressors
Blowers
Lubrication
Failure
Over, under or
improper lube;
heat & moisture
Spectrographic
& ferrographic
analysis
Electrical
Equipment
Motors, Cables
Starters,
Transformers
Insulation
Failure
Heat & Moisture Time/resistance
test,I/R scans,
oil analysis
Corona
Discharge
Moisture,
splice methods
Ultrasound
Heat Transfer
Equipment
Exchangers
Condensers
Fouling
Sediment &
material build-up
Heat transfer
calculations
Containment
& Transfer
Tanks,
Piping
Reactors
Corrosion
Chemical
attack
Corrosion
meters,
acoustic
emissions
Stress cracks
Metal fatigue Thickness
checks
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Mechanical Integrity Program
Mechanical Integrity Program
Definition of Mechanical Integrity
Those aspects of production, maintenance, technical,
quality and purchasing which ensure that there is a
system in place for the proper design, construction, on-
going integrity and reliability of the process equipment
over the entire lifecycle of the process.
Mechanical Integrity Program includes
Identify Critical Equipment
Conduct Predictive Maintenance
Establish Type and Frequency of Testing
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Mechanical Integrity Program
Mechanical Integrity Program
Periodic
Monitoring
Repair/Replacement
Equipment
Measurements Measurements
Meet Meet
Engineering Engineering
Limits? Limits?
Determine Corrective
Action
Analyze Problem
Yes
No
Ref: Engineers Digest, Feb., 1996, p.30
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Mechanical Integrity Program
Mechanical Integrity Program
Obtain Types and Frequencies of Predictive
Maintenance
Company Experience
Equipment Manufacturers Experience
Industry Data
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operational Safety
Operational Safety
Element #7
Element #7
Training
Training
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Training
Training
Who in Your Operations Should Be Trained?
Operators
Maintenance
Engineers
Contractors
What Should the Training Include?
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Training
Training
1. Understanding the Process Information
MSDSs
Identify hazards of materials
Understand how to handle materials
Fight fires involving these materials
Disposal of materials
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Training
Training
Sample MSDSs
R
R
-
-
34 Platforming Catalyst
34 Platforming Catalyst
Molsiv
Molsiv
Adsorbents 4A
Adsorbents 4A
-
-
DG 1/16
DG 1/16
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Training
Training
1. Understanding the Process Information
MSDSs
Identify hazards of materials
Understand how to handle materials
Fight fires involving these materials
Disposal of materials
PFDs/P&IDs
Understand the process
Know the equipment involved in the process
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Training
Training
1. Understanding the Process Information
MSDSs [by Safety and Industrial Hygienist]
Identify hazards of materials
Understand how to handle materials
Fight fires involving these materials
Disposal of materials
PFDs/P&IDs
Understand the process
Know the equipment involved in the process
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Training
Training
2. Operating Procedures
Startup, Normal and Shutdown
Emergency Scenarios
Testing of the Operators
Refresher Sessions
Changes Made
Periodic
3. Maintenance Procedures
Maintenance Personnel
Operations Personnel, who conduct maintenance
work
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Training
Training
2. Operating Procedures
Startup, Normal and Shutdown
Emergency Scenarios
Testing of the Operators
Refresher Sessions
Changes Made
Periodic
3. Maintenance Procedures
Maintenance Personnel
Operations Personnel, who conduct maintenance
work
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Training
Training
Who in Your Operations Should Be Trained?
Operators
Maintenance
Engineers
Contractors
What Should the Training Include?
Who Should Do The Training?
Operations Supervision
Engineers
Maintenance Experts
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operational Safety
Operational Safety
Element #8
Element #8
Modifications
Modifications
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Modifications
Modifications
Reassess and Address Hazards after making
the Modifications
Includes Significant Changes
Addition of equipment
Running additional (or bypass) lines
Changing operating procedures (especially batch)
Does NOT Include Changes in Kind
Use an Appropriate PHA Method
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Modifications
Modifications
Types of Hazard Analyses
Hazard & Operability (HAZOP) Study Hazard & Operability (HAZOP) Study for Process
What If? Analysis What If? Analysis for Process
Checklist
Failure Modes & Effects Analysis Failure Modes & Effects Analysis for Equipment
Fault Tree Analysis
Process HSE Review
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Modifications
Modifications
How is Information from PHAs for
Modifications Used?
Revise Operating Procedures
Must reflect changes
Revise Mechanical Integrity Program
Add/Delete Equipment Covered
Ensure Maintenance Understands MI Changes
Ensure Operator are Aware of
Changes Made to the Process Design
Changes Made to Equipment and the MI Program
Impact on Procedures/Highlighting the Changes
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Modifications
Modifications
How is Information from PHAs for
Modifications Used?
Revise Operating Procedures
Must reflect changes
Revise Mechanical Integrity Program
Add/Delete Equipment Covered
Ensure Maintenance Understands MI Changes
Ensure Operator are Aware of
Changes Made to the Process Design
Changes Made to Equipment and the MI Program
Impact on Procedures/Highlighting the Changes
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Modifications
Modifications
Sample Checklist
Facility & Operational Change
Facility & Operational Change
Review
Review
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operational Safety
Operational Safety
Element #9
Element #9
Pre
Pre
-
-
Startup Safety Reviews
Startup Safety Reviews
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Pre
Pre
-
-
Startup Safety Reviews
Startup Safety Reviews
When to Conduct PSSRs
New Process/Facility
Significantly Modified
Significant Procedural Changes
Recommissioned/Idled Process
Documentation
Identify Corrections,
Assign Responsibilities and
Ensure that Action Items are Closed
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Pre
Pre
-
-
Startup Safety Reviews
Startup Safety Reviews
When to Conduct PSSRs
New Process/Facility
Significantly Modified
Significant Procedural Changes
Recommissioned/Idled Process
Documentation
Identify Corrections,
Assign Responsibilities and
Ensure that Action Items are Closed
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Pre
Pre
-
-
Startup Safety Reviews
Startup Safety Reviews
Sample Checklist
Pre
Pre
-
-
Startup Safety Review
Startup Safety Review
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operational Safety
Operational Safety
Element #10
Element #10
Decommissioning/
Decommissioning/
Recommissioning
Recommissioning
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Decommissioning /
Decommissioning /
Recommissioning
Recommissioning
What is Decommissioning?
Removing process equipment from service, isolating
and securing the equipment from operations.
Do not plan to use the equipment anytime in the near
future.
How is Decommissioning different from
Idling?
Temporary discontinuation of an operation according
to accepted shutdown procedures.
There is a plan to restart the operation in the near
future.
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Decommissioning /
Decommissioning /
Recommissioning
Recommissioning
Establish Procedures
Review Impact on Active Operations
Temperature Control
Pressure Control
Emptying Vessel, Equipment and Lines
Blinding/Disconnecting
Maintain Sound HSE Performance
Proper Maintenance
Fire Fighting Capability
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Decommissioning /
Decommissioning /
Recommissioning
Recommissioning
Establish Procedures
Review Impact on Active Operations
Temperature Control
Pressure Control
Emptying Vessel, Equipment and Lines
Blinding/Disconnecting
Maintain Sound HSE Performance
Proper Maintenance
Fire Fighting Capability
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Decommissioning /
Decommissioning /
Recommissioning
Recommissioning
Sample Checklists
Idling & Decommissioning
Idling & Decommissioning
Plants
Plants
Recommissioning
Recommissioning
Plants
Plants
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Operational Safety
Operational Safety
Element #11
Element #11
Process Incident Investigations
Process Incident Investigations
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Process Incident Investigations
Process Incident Investigations
What should be Investigated?
Process-Related Incidents
Actual
Near Misses
What are you trying to Determine?
Root Causes
Conditions
Actions
Why? Why? Why? Why? Why?
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Process Incident Investigations
Process Incident Investigations
What should be Investigated?
Process-Related Incidents
Actual
Near Misses
What are you trying to Determine?
Root Causes
Conditions
Actions
Why? Why? Why? Why? Why?
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Uranium Processing Plant
Uranium Processing Plant
Can It happen Here? page 47,
Newsweek, Oct. 11, 1999
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Uranium Processing Plant
Uranium Processing Plant
Can It happen Here? page 47,
Newsweek, Oct. 11, 1999
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Process Incident Investigations
Process Incident Investigations
What are some of the Root Causes that
came out of the Investigation of this
Incident?
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Process Incident Investigations
Process Incident Investigations
What are some of the Root Causes that
came out of the Investigation of this
Incident?
Inadequate Procedures
Not specifying quantities of enriched uranium
No emphasis on why the materials needed to be
added slowly
Inadequate training and testing
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Process Incident Investigations
Process Incident Investigations
What are some of the Root Causes that
came out of the Investigation of this
Incident?
Inadequate Procedures
Not specifying quantities of enriched uranium
No emphasis on why the materials needed to
be added slowly
Inadequate training and testing
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Process Incident Investigations
Process Incident Investigations
For Any Incident Investigation, How Can We
Prevent Recurrence?
Understand the Problem that Caused the Incident
Correct the Problem
Learn and Apply Solution to Similar Operations
& Equipment
Share the Resolution with Other Units
Communicate with Plant Personnel
Revise Future Designs
Share with
Other Company Sites
Industry (if possible)
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Process Incident Investigations
Process Incident Investigations
For Any Incident Investigation, How Can We
Prevent Recurrence?
Understand the Problem that Caused the Incident
Correct the Problem
Learn and Apply Solution to Similar Operations
& Equipment
Share the Resolution with Other Units
Communicate with Plant Personnel
Revise Future Designs
Share with
Other Company Sites
Industry (if possible)
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Engineering Impact
Engineering Impact
As an Engineer...
How are you involved in
Operational Safety activities?
Directly Involved
Provide Input
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Field Safety for Engineers
Field Safety for Engineers
Parting Tips for
Personally
Staying Safe
Preparation
Personal
Protective
Equipment
Medical
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.
Field Safety for Engineers
Field Safety for Engineers
UOP
UOP
Field Safety Handbook
Field Safety Handbook
2003 ENGINEERING DESIGN SEMINAR LIMITED DISTRIBUTION: This material is UOP LLC technical information of a confidential
nature for use only by personnel within your organization requiring the information. The material shall not be reproduced in any manner or
distributed for any purpose whatsoever except by written permission of UOP LLC and except as authorized under agreements with UOP LLC.