Guidelines For Writing Effective Operating And Maintenance Procedures

The EPA investigation of a 1994 chemical plant tragedy concluded that "the explosion resulted from a lack of written safe operating procedures..." While good written procedures can't guarantee zero accidents, they can reduce the number of accidents caused by human error. This new book shows how to remedy this problem through selecting and implementing actions that promote safe, efficient operations and maintenance, improve quality, continuity, profitability and cost control, build upon and record process experience, and promote the concept that operating and maintenance procedures are vital plant components. It includes practical samples of procedure formats, checklists and many references.

The EPA investigation of a 1994 chemical plant tragedy concluded that "the explosion resulted from a lack of written safe operating procedures8230;" While good written procedures can't guarantee zero accidents, they can reduce the number of accidents caused by human error. This new book shows how to remedy this problem through selecting and implementing actions that promote safe, efficient operations and maintenance, improve quality, continuity, profitability and cost control, build upon and record process experience, and promote the concept that operating and maintenance procedures are vital plant components. It includes practical samples of procedure formats, checklists and many references.

This book is an update and expansion of topics covered in Guidelines for Mechanical Integrity Systems (2006). The new book is consistent with Risk-Based Process Safety and Life Cycle approaches and includes details on failure modes and mechanisms. Also, example testing an inspection programs is included for various types of equipment and systems. Guidance and examples are provided for selecting and maintaining critical safety systems.

In recent years, process safety management system compliance audits have revealed that organizations often have significant opportunities for improving their Mechanical Integrity programs. As part of the Center for Chemical Process Safety's Guidelines series, Guidelines for Mechanical Integrity Systems provides practitioners a basic familiarity of mechanical integrity concepts and best practices. The book recommends efficient approaches for establishing a successful MI program.

Human Factors Handbook for Process Plant Operations Provides clear and simple instructions for integrating Human Factors principles and practices in the design of processes and work tasks Human Factors, the science of interaction between humans and other elements of a system, draws from disciplines such as psychology, ergonomics, anthropometrics, and physiology to understand how and why people behave and perform as they do—and how best to support them in performing tasks. The goals of the Human Factors approach are to improve human reliability, minimize the risk from human error, and optimize the working environment, human wellbeing, and overall system performance. Human Factors Handbook for Process Plant Operations guides supervisors, managers, and engineers on incorporating Human Factors principles and practices into plant maintenance and operations. With thorough and accessible coverage of all Human Factors topics of relevance to process industries, this easy-to-use handbook uses real-world anecdotes and case studies to demonstrate effective training and learning, task planning, communications, emergency response, risk and error management, and more. Throughout the text, the authors offer valuable insights into why people make mistakes while providing advice on how to help workers perform their process operational tasks successfully. Explains all essential Human Factors concepts and knowledge with clear descriptions and illustrative examples Offers actionable advice and models of good practice that can be applied to design, process operations, start-ups and shut-downs, and maintenance Addresses job aids, equipment design, competence, task support, non-technical skills, working with contractors, and managing change Discusses how lack of Human Factors considerations during the engineering design phase can adversely affect safety and performance Describes how to use indicators to both recognize and learn from human error and performance issues Written by highly experienced operating and maintenance personnel, Human Factors Handbook for Process Plant Operations is an indispensable resource for everyone involved with defining, planning, training, and managing process operations, maintenance, and emergency response in the food, pharmaceutical, chemical, petroleum, and refining industries. The missions of both the CCPS and EI include developing and disseminating knowledge, skills and good practices to protect people, the environment, and property by bringing the best knowledge and practices to industry, academia, governments and the public around the world through collective wisdom, tools, training and expertise. The CCPS, an industrial technology alliance of the American Institute of Chemical Engineers (AIChE), has been at the forefront of documenting and sharing important process safety risk assessment methodologies for more than 35 years and has published over 100 books in its process safety guidelines and process safety concept book series. The EI’s Technical Work Program addresses the depth and breadth of the energy sector from fuels and fuels distribution to health and safety, sustainability and the environment. The EI program provides cost-effective, value-adding knowledge on key current and future international issues affecting those in the energy sector.

Organized into ten chapters, this book provides a discussion of the roles of first- and second-line operations and maintenance supervisors through the various phases of the life cycle of a plant. Each of the remaining chapters treats one of the phases of the life cycle of a plant: design, construction, pre-startup and commissioning, startup, operation, maintenance, shutdown, decommissioning, and demolition. Each chapter provides guidance, tools, and checklists to assist supervisors in implementing and practicing of process safety program principles. Includes a substantial glossary and appendices. Annotation copyright by Book News, Inc., Portland, OR

This book provides guidance on characterizing, recognizing, and responding to warning signs to help avoid process incidents and injuries before they occur. The guidance can be used by both process safety management (PSM) professionals in evaluating their processes and PSM systems as well as for operators who are often the frontline defense against process incidents. Warning signs may consist of process deviations or upsets, instrumentation warnings or alarms, past operating history and incidents, observable problems such as corrosion or unusual odors, audit results indicating procedures are not being followed, or a number of other indicators. Filled with photos and practical tips, this book will turn anyone in a process plant into a hazard lookout and will help prevent potential incidents before they turn into catastrophic events.

In today’s competitive economy, companies often augment in-house production by outsourcing chemical reaction processes and distillation, drying, formulating, blending, and packaging operations. While most of these tolling, or contracted manufacturing services, proceed without incident, recent major accidents have pointed to weaknesses in some tolling arrangements, such as reactivity of materials and processes. This Guidelines book provides the reader with proven procedures to improve process safety throughout the life cycle of a contracted manufacturing operation. Extensive checklists and examples used throughout the book make it a valuable learning tool and reference for companies conducting toll manufacturing, or considering outsourcing manufacturing operations.