PSM Project Management Compliance Strategy
Employing Project Management Process Principles to Implement Process Safety Management (PSM) Compliance Strategy.
I. Initiating Project Management Planning Process Group (1)
i. Project Integration Management
i. Develop PSM Project Management Charter
a. Sr. Director of Process Safety Excellence
b. Director of Safety & Health
c. Division Health and Safety Manager
ii. Identify Stakeholders
II. Planning Process Group (2)
a. Develop PSM Project Management Action Plan
b. Plan Scope of Action
c. Identify PSM requirements
i. OSHA 29CFR 1910.119 (3)
i. Audit PSM Program to determine compliance gaps
ii. Identify responsibilities at department level
iii. Apply (RAGAGEP) Recognized and Generally Accepted Good Engineering Practice utilizing DIERS methodology to provide a system of relief device calculation, documentation and storage that meets Code compliance, Corporate standards, API, CGS, DIERS, and NFPA guidelines to comply with OSHA 29CFR 1910.119a and eliminate process safety gaps at plant sites.
iv. Collect Requirements
i. Identify process safety gaps
a. Employee Participation (4)
a. EH & S
b. Collect and Maintain Process Safety Information (5)
a. Engineering & Operations
c. Perform Process Hazard Analysis (6)
a. EH& S, Engineering, Operations, Safety
d. Develop and Maintain Accurate Operating Procedures (7)
a. Operations
e. Provide Employee Training (8)
a. EH&S, Engineering, Operations, Maintenance
f. Provide Contractor Screening Training (9)
a. EH&S, Engineering, Operations, Maintenance
g. Pre-Start-up Safety reviews (10)
a. EH&S, Engineering, Operations, Mechanical
h. Mechanical Integrity (11)
a. Mechanical, Maintenance
i. Hot Work Permits (12)
a. EH&S,
j. Management of Change (13)
a. EH&S, Operation, Engineering, Mechanical, Maintenance,
k. Incident Investigation (14)
a. EH&S, Engineering, Operations, Mechanical, Maintenance
l. Emergency Preparedness (15)
a. EH&S
m. OSHA Compliance Audit (16)
a. EH&S, Engineering, Operations, Mechanical, Maintenance,
n. No Trade Secrets (17)
a. EH&s
d. Create Work break-down Schedule (WBS) (18)
i. Phase I (18a)
a. Locate and evaluate standard operating procedures (SOP?s)
b. Pull P&ID?s, PFD?s, MSD sheets, etc. and update
c. Identify relief devices & control systems
d. Identify protected equipment
e. Locate equipment data sheets
a. Vessels (certifications)
b. Pumps
c. Filters
d. Compressors
e. Others
f. Locate design base documentation
g. Review documentation or lack thereof
h. Walk-down process
i. Perform Assessment
j. Generate Assessment Report
ii. Phase II (18b)
a. Identity Hazop Action items
b. Determine applicable Code Compliance
c. Define credible scenarios
d. Calculate required capacity for each scenario
e. Determine worst-case scenario & design basis
f. Select standard relief orifice and capacity
g. Perform inlet/outlet pressure drop
h. Assess & Meet Code compliance
i. Compare existing design with proposed
j. Make recommendations
k. Generate design base documentation
l. Generate specification sheets
m. Save to Relief Design database
e. Project Time Management (19)
i. Plan Schedule
i. Select Project management software
ii. Define Activities
i. See WBS above
iii. Sequence Activities
iv. Estimate Activity Resources
v. Estimate Activity duration
vi. Develop Schedule
vii. Control Schedule
f. Project Cost Management (20)
i. Plan Cost Management
ii. Estimate Cost
iii. Determine Budget
g. Project Quality Management (21)
i. Plan Quality Management
i. Review PSM Audit Findings
a. Close action items
ii. Review design base calculations
a. Close action items
iii. Review design base documentation
a. Close action items
iv. Bi-weekly Review conference
h. Human Resource Management (22)
i. Plan Human Resource Management
ii. Acquire Project Team
i. EH &S
ii. PSM Manager
iii. Process Engineering
iv. Projects
v. Operations
vi. Mechanical
vii. Maintenance
viii. Instruments and Control
ix. Facilities Management
x. Reliability Engineer
xi. Computers & Software Design
xii. Electrical Classification and Controls
xiii. Corrosion Expert
xiv. Reactivity Expert
xv. PHA Facilitator
xvi. Relief Design Expert
xvii. DIERS Two-phase Expert
xviii. Lead Process Safety Engineer
iii. Develop Project Team
i. Provide Relief device training
a. Provide critical Code compliance
b. Provide design basis strategies
c. Provide selection strategy
d. Provide maintenance strategy
iv. Manage Project Team
i. Health & Safety Manager
ii. PSM Manager
i. Project Communication Management (23)
i. Plan Communication Management
i. Determine e-mail list
j. Project Risk Management (24)
i. Plan Risk
ii. Identify Risk
i. Reactivity
ii. Compressed Gases
iii. High Pressure
iv. High Temperatures
v. Fire
vi. Explosion Hazards
vii. Dust Hazards
iii. Perform Qualitative Risk Analysis
i. Prioritize individual risk (critical or non-critical)
ii. Assessing probability, occurrence and impact
a. Prepare Probability & Impact Matrix
a. Determine threshold
iv. Perform Quantitative Risk Analysis
i. Numerically analyze combined effect of risk on project
a. Performed on critical risk
v. Plan Risk Resources
i. Implement Risk Response
a. Eliminate
b. Mitigate
c. Control
d. Emergency Response
k. Project Procurement Management (25)
i. Plan Procurement Management
i. Relief valves
ii. Piping
iii. Equipment
iv. Software
v. Books
vi. Instruments
vii. Other
l. Project Stake-Holder Management (26)
i. Identify Stakeholders
i. Director Health & Safety
ii. Division Health & Safety
iii. PSM Manager
iv. Plant Manager
v. EHS Manager
vi. Process Safety Leader
vii. Process Safety Engineer
viii. Operations Manager
ix. Facilities Manager
x. Maintenance Manger
xi. Engineering Manager
xii. Process Manager
xiii. Project Manager
xiv. Safety Training Coordinator
xv. Systems Plant Engineers
xvi. Technical Assistants
xvii. Employees
xviii. Community at large
ii. Manage Stake-holder Engagement
PSM Project Management Compliance Strategy
Employing Project Management Process Principles to Implement Process Safety Management (PSM) Compliance Strategy.
Follow procedures outlined in ?Guidelines for Pressure Relief and Effluent Handling?, American Institute of Chemical Engineers (AIChE), Center for Chemical Process Safety (CCPS) as compliance strategy to meet OSHA 29CFR1910.119 Process Safety Management Standard
"For example the AIChE has published technical reports on topics such as two-phase flow for venting devices. This type of technically recognized report would constitute good engineering practice." OSHA Appendix C 1910.119 Compliance Guidelines and Recommendations for Process Safety Managment.
III. Executing Process Group (27)
a. Project Integration Management
i. Direct & Manage Project Work
ii. Manage Project Knowledge
i. Determine & Acquire Resources Required to Eliminate Gaps
a. Code Requirements
a. ASME Code
b. Standards Required
a. Emergency Relief Design Procedure Manual
b. API 520/521
c. NFPA 30
d. NFPA 58
e. Compressed Gas Association Standard (CGA)
c. Books
a. Guidelines for Pressure Relief and Effluent Handling
a. Super Chems for DIERS Lite software (free w/ book)
b. CCFlow software (free w/ book)
c. TPHEM Software (free w/ book)
d. Software Resources
a. Aspen
b. Chem CAD
c. Sinet
d. Mach II CDS, PSM Network System
e. CCFlow
f. Super Chems (Expert or Professional)
b. Project Quality Management (20)
i. Perform Quality Assurance
i. Evaluate Resources and Complete Assessment
a. ASME Code relevant sections
b. Compressed Gas Standard
c. API 520/521 Relevant sections
d. NEPA 30
e. NEPA 58
f. Guidelines for Pressure Relief and Effluent Handling
g. Emergency Relief Design Manual
ii. Assess & Extract Critical Points for Stakeholders
a. Overview
b. Code Requirements
b. Hazop Review
c. Device Selection
d. Design
e. Installation
f. Maintenance
g. Calculations
h. Documentation
i. Storage
j. Retrival
iii. Software Evaluation
a. Mach II CDS, PSM Network System
a. Select Test Case
a. Fire Case (28)
b. DIERS Benchmarks (AIChE)
a. Liquids Case 8 (29)
b. Vapors/ Gases Case 1 (30)
c. Perform two-phase flow evaluation (31)
a. DIERS Benchmarks (32)
i. Two-phase flashing flow (33)
ii. Hybrid flow (34)
iii. Frozen flow (35)
iv. Churn-turbulent flow (36)
v. Homogeneous flow (37)
vi. High viscosity flow (38)
c. Determine two-phase homogeneous fire relief rate (C) (D)
d. Determine maximum fluid flux(Gmax) (E) (F) (G) (H) (I)
e. Determine two-phase orifice size or relief capacity (J)
f. Determine two-phase piping design (K) (L) (M)
g. Use coupling equation to determine bubbly flow regime (N) (O)
h. Use coupling equation to determine churn-turbulent flow regime (P) (S)
I. Determine capacity for Runaway Reaction (T) (U)
b. Compare software results
a. Resolve differences
a. Contact DIERS
a. Discussed removal of entrance/exit & expansion losses
b. Contact i/oMosaic about Super Chems software
a. Discuss why program give same results both for 4? and 6? discharge pipe. Ask why program does not allow removal of expansion resistance.
c. Determine Software Program Advantages
a. Mach II CDS Network System
a. Provides complete detailed design record and specification sheets all stored electronically
b. CCFlow
a. Great for quick calculations
b. Free with CCPS Book
c. Super Chems Lite from ioMosaic
a. Should have latest design methodology
b. Has physical property database
c. Free with purchase of CCPS Book
d. Chem Cad
a. Simulation program
b. Physical properties generated
e. Sinet
a. Simulation program
b. Has physical property data base
d. Determine Software Program Disadvantages
a. Mach II CDS, PSM Network System
a. No physical property database
b. CCFlow
a. No physical Property database
b. One-page documentation
c. No spec sheets
c. Super Chems Lite
a. Difficult to learn
b. Lite version limited will need DIERS and Expert versions
c. Does not show physical properties
d. Does not show pipe equivalent lengths
e. Does not perform two-phase test
f. Does not allow two-phase modeling in vessel
g. No coupling equation available
d. Chem Cad
a. Not sure if it calculates choke flowrate
b. Not a relief design record
c. No Spec sheets
e. Sinet
a. No relief device model
b. Must model by using pipe flow sizing
e. Resolve relief entrance and exit loss controversy
a. Contacted Harold Fisher to confirm inlet loss is recoverable in relief valve so no entrance losses. Exit to atmosphere is large expansion and hence no exit loss. Rupture Disc has 1.0 entrance lose and no exit loss for turbulent flow, and 2.0 entrance loss for laminar flow.
f. Resolve expansion loss controversy
a. Received e-mail from Harold Fisher of DIERS
a. Calculated Head loss caused by changes in pipe size (41a) a. William B. Hooper Monsanto Co. Chemcial Engineering November 7, 1989
b. The two-K method predicts (41b)
a. William B. Hooper Monsanto Co. Chemical
c. Sensitivity of relief valves to inlet and outlet line lengths
a. Brice A. Van Boskirk, Velsicol chemical Co. Chemical Engineering August 1982
iv. Determine Final Relief Design Methodology
c. Project Human Resource Management (42)
i. Acquire Project Team
i. Identify and Secure Relief Design Experts
a. PSM Engineer
a. Acts of checker and can perform quick calculations
b. Utilizing Chem CAD, Aspen or other
c. Helps to Provides physical property data as required
d. Helps to resolves differences
e. Must Agrees on methodology
f. Must gain confidence in results
g. Must develop trust in one another
ii. Identify who is responsible for Corporate Relief Design Manual
a. Process Engineer (TBD)
a. Updates Relief Design Manual
b. Implements Corporate Standards
iii. Identify Codes and Standards Expert
a. OSHA 29 CFR 1910.119
b. ASME Section 1 valves
a. Boilers
c. ASME Section IV valves
a. Hot water heaters
d. ASME Section VIII valves
a. Pressure Vessels
e. ASME Section B31.3 valves
a. Process piping
f. NFPA 30 valves
a. Low pressure storage tanks
g. NFPA 58 valves
a. Propane storage tank relief
h. CGA S-1.3 valves
a. Compressed Gas Standards
i. API 2000
a. Storage tanks
ii. Develop Project Team
i. Provide in-house Relief design training to plant personnel
a. Introduction to Design (43)
b. Code Requirements (44)
c. Purpose of Hazop Reviews (45)
d. Selection (46)
e. Design Scenario Calculations (47a)
f. Design orifice size (47b)
g. Design Pressure drop calculations (48)
h. Installation (49)
i. Maintenance (50)
iii. Manage Project Team
i. Hazop Review Kick off to Relief Design
ii. Start Hazop on each process area to determine credible scenarios
a. Process Engineering
b. Subject Matte Experts
c. PSM Engineers
d. Mechanical
e. Operations
f. Maintenance
iii. Perform relief device Calculations based on Hazop Review of Circuit (51)
a. Calculate required capacity for each credible scenario (52)
b. Calculate required orifice size for each credible scenario (53)
c. Select standard orifice size
d. Determine rate capacity of standard orifice
e. Perform inlet/outlet pressure drop calculations (54)
f. Ensure Code compliance (55)
g. Select or verify existing relief device
h. Create specification sheet
i. Make recommendations
j. Generate design record
k. Provide electronic storage of records
d. Project Communication Management
i. Manage Communication
i. Written
ii. Formal or informal
iii. Presentations
iv. Conversations
v. E-mail
vi. Fax
vii. Telephone
viii. Blogger
ii. Monitor Communication
e. Project Procurement Management
i. Conduct Procurement
i. Equipment
ii. Piping
iii. Relief valves
iv. Conservation vents
v. Software
vi. Services
f. Project Stakeholder Management
i. Manage Stakeholder Engagement
i. Determine needs
ii. Proper Communication
iii. Keep Informed
iv. Meet Expectation
IV. Monitor & Control Process Group
a. Project Integration Management
i. Monitor and Control Project Work
ii. Perform Integrated Change Control
b. Project Scope Management
i. Validate Scope
ii. Control Scope
c. Project Time Management
i. Control Schedule
d. Project Quality Management
i. Control Quality
e. Project Human Resource Management
i. Control Resources
f. Project Communication Management
i. Monitor Communication
g. Project Risk Management
i. Monitor Risk
i. Positive risk
ii. Negative risk
iii. Pure risk
iv. Business risk
v. Risk Tolerance
vi. Risk Threshold
h. Project Procurement Management
i. Control Procurement
i. Project Stakeholder Management
i. Monitor Stakeholder Engagement
V. Close Project or Phase
