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.      Ehamp; 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 Engineers

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 Stakeholder 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 Stakeholder 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.

"Process Safety Management (PSM) is the proactive identification, evaluation, and mitigation or prevention of chemical releases that could occur as a result of failures in process, procedures or equipment."  OSHA 29CFR 1910.119

"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 Management.

"In general, the most stringent relief requirement is due to all-liquid venting. Since this venting mode is unlikely for a top venting ERS design, the homogeneous -vessel behavior offers the next most stringent requirement and is therefore the recommended design approach for this configuration. Sizing based on all-vapor venting is both unrealistic and unsafe." J.C. Leung Fauske and Associates, Inc. AIChE Journal October 1986

Process safety Information (PSI) - should include a complete compilation of process safety information before conducting any required process hazard analysis (PHA). Guidelines for Pressure Relief and Effluent Handling, AIChE, CCPS 2nd Edition 2017.

Project Management Plan

I.      Initiating Process Group (1-PMP)

        a.      Project Integration Management

                  i.     Develop PSM Project Management Charter

                          i.    Sr.  Director of Process Safety Excellence

                         ii.    Director of Safety & Health

                        iii.   Division Health and Safety Manager

                 ii.     Identify Stakeholders

II.     Planning Process Group (2-PMP)

        a.     Project Integration Management

                 i.     Develop PSM Project Management Plan

        b.     Project Scope Management

                 i.      Plan Scope

                ii.     Collect PSM requirements

                         i.    OSHA 29CFR 1910.119 (3-OSHA Standard)

                                a.    Prepare PSM Audit to determine compliance gaps (4-OSHA)

                                        a.      Employee Participation (5-OSHA Element # 1)

                                                  a.     EH & S

                                        b.      Collect and Maintain Process Safety Information    (6-OSHA Element #2)    (7-CCPS Procedures)

                                                  a.     Engineering & Operations

                                        c.       Perform Process Hazard Analysis  (8-OSHA Element #3 )    (9-CCPS Procedures )

                                                  a.     EH & S, Engineering, Operations, Safety

                                        d.      Develop and Maintain Accurate Operating Procedures (10-OSHA Element # 4)

                                                 a.     Operations

                                        e.      Provide Employee Training   (11-OSHA Element # 5)

                                                 a.     EH&S, Engineering, Operations, Maintenance

                                        f.      Provide Contractor Screening Training   (12-OSHA Element # 6)

                                                 a.     EH&S, Engineering, Operations, Maintenance

                                       g.      Pre-Start-up Safety reviews (13-OSHA Element # 7)

                                                a.     EH&S, Engineering, Operations, Mechanical

                                       h.     Mechanical Integrity (14-OSHA Element # 8)

                                                a.     Mechanical, Maintenance

                                       i.       Hot Work Permits (15-OSHA Element # 9)

                                                a.     EH&S,

                                       j.      Management of Change (16-OSHA Element # 10)

                                               a.     EH&S, Operation, Engineering, Mechanical, Maintenance,

                                      k.      Incident Investigation (17-OSHA Element # 11)

                                               a.     EH&S, Engineering, Operations, Mechanical, Maintenance

                                       l.      Emergency Preparedness (18-OSHA Element # 12)

                                               a.     EH&S

                                     m.     OSHA Compliance Audit (19-OSHA Element # 13)

                                               a.     EH&S, Engineering, Operations, Mechanical, Maintenance,

                                     n.      No Trade Secrets (20-OSHA Element # 14)

                                               a.     EH&S

                iii.      Define Scope (21-PMP)

                           i.       Identify responsibilities at department level

                          ii.       Determine Deliverables

                                     a.      PSM Program Procedures

                                     b.      Employee Access to PSI

                                    c.       PHA's

                                    d.      Operating Procedures (SOP's)

                                    e.      Employee Training Program

                                    f.      Contractor Screening and Training Program

                                    g.      Pre-Start-up Safety Reviews

                                    h.      Mechanical Integrity Program

                                              a.      Equipment database

                                                        a.     Inspection &Certification of Pressure vessels

                                              b.      Relief device database

                                              c.      Instrument database

                                     i.       Hot Work Permit Authorization Program

                                     j.       Management of Change (MOC) Procedure

                                              a.      Capital Projects

                                              b.      Modifications

                                                       a.     Process

                                                       b.     Procedure

                                                       c.     Equipment

                                    k.      Incident Investigation Procedures

                                     l.      Emergency Preparedness & Response Procedures

                                   m.      PSM Audit Procedures

                                    n.      No Trade Secrets

                         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.       Identify process safety gaps

                 iv.      Create Work break-down Schedule (WBS) (22-PMP)  (23-CCPS Design Approach)

                            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

                   v.      Validate Scope

                             i.      Accepted Deliverable

                  vi.      Control Scope

                             i.        Work Performance Info

                            ii.      Change Request

         c.      Project Time Management (24-PMP)

                   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

        d.     Project Cost Management (25-PMP)

                         i.      Plan Cost Management

                        ii.      Estimate Cost

                       iii.      Determine Budget

       e.     Project Quality Management (26-PMP)

                         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.     Review PSM Audit Findings

                                         a. Close action items                                      

                               iv.    Hold Bi-weekly Review meetings

       f.       Human Resource Management (27-PMP)

                        i.      Plan Human Resource Management

                       ii.      Estimate Activity Resources

                      iii.      Acquire Project Team (Define Roles & Responsibilities)

                                 i.     Project Manager

                                ii.     Health & Safety Manager

                               iii.     PSM Manager

                               iv.     Process Engineer

                                v.     Health & Safety Coordinator

                               vi.    Sr. Safety & Health Specialist

                              vii.    Operations Manager

                             viii.    Mechanical Manager

                               ix.    Maintenance Manger

                                x.    Instruments and Control Manger

                              xi.     Facilities Manager

                             xii.     IT Manager

                            xiii.     Reliability Engineer

                            xvi.     Process Safety Manager & Mechanical Integrity Leader

                             xv.     Software Design Engineer

                            xvi.     Electrical Classification Specialist

                           xvii.     Corrosion Expert

                          xviii.     Reactivity Expert

                            xix.     PHA Facilitator

                             xx.     Relief Design Expert

                          xxi.       DIERS Two-phase Expert

                           xxii.     Lead Process Safety Engineer

                         xxiii.      Health & Safety Coordinator

                          xxiv.     Sr. Safety & Health Specialist

                      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

        g.     Project Communication Management (28-PMP)

                  i.      Plan Communication Management

                                i.     Determine e-mail list

                 ii.      Manage Communication

                iii.      Monitor Communication

h.     Project Risk Management (29-PMP)

 Note: Engineering Judgment should be used to match the extent of the relief protection effort to the severity of the consequences. A risk assessment that considers both the consequences and likelihood of the over-pressure event      can be used to assist in this engineering judgment. (Guidelines for Pressie Relief and Effluent Handling 2nd Edition              2017)

                  i.      Plan Risk

                 ii.      Identify Risk

                          i.     Reactivity

                         ii.     Compressed Gases

                        iii.     High Pressure Processes

                        iv.     High Temperatures Processes

                        v.      Fire

                       vi.     Explosion Hazards

                      vii.     Dust Hazards

                     viii.     Toxic Vapor Clouds

                iii.      Perform Qualitative Risk Analysis

                          i.     Prioritize individual risk (critical or non-critical)

                         ii.     Assess probability, occurrence and impact

                                   a.     Prepare Probability & Impact Matrix

                                            a.      Determine threshold

                iv.      Perform Quantitative Risk Analysis

                          i.     Numerically analyze combined effects of risk on project

                                 a.     Performed on critical risk

                v.      Plan Risk Resources

                         i.        Plan Risk Response

                                   a.     Eliminate

                                   b.     Mitigate

                                   c.     Control

                                   d.     Emergency Response

i.        Project Procurement Management (30-PMP)

                 i.      Plan Procurement Management

                          i.     Relief valves

                         ii.     Piping & fittings

                        iii.     Equipment

                        iv.     Software

                         v.     Books

                        vi.    Instruments & Controls

                      vii.     Other

j.        Project Stake-Holder Management (31-PMP)

                         i.      Identify Stakeholders

                                 i.     Sr. Director Process Safety Excellence

                                ii.     Director Health & Safety

                               iii.     Division Health & Safety Manager

                               iv.     PSM Manager

                                v.     Plant Manager

                              vi.     Health & Safety Manager

                             vii.     Process Safety Leader

                            viii.     Process Safety Engineer

                              ix.     Operations Manager

                               x.     Facilities Manager

                              xi.    Maintenance Manger

                             xii.    Engineering Manager

                            xiii.    Process Manager

                            xiv.    Project Manager

                             xv.    Safety Training Coordinator

                            xvi.    Systems Plant Operating Engineer

                           xvii.    Health & Safety  Coordinator

                          xviii.    Sr. safety & Health Specialist

                           xix.     Technical Assistants

                           xx.      Process Safety Manager & Mechanical Integrity Leader

                           xx.     Employees

                           xxi.     Community at large

                           

III.      Executing Process Group (32-PMP)

           a.     Project Integration Management

                 i.      Direct & Manage Project Work

                ii.      Manage Project Knowledge

                         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.

                         Process Safety Management (PSM) is the proactive identification, evaluation, and mitigation or prevention                              of chemical releases that could occur as a result of failures in process, procedures or equipment.  OSHA                                  29CFR 1910.119

                        "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 Management.

                        In general, the most stringent relief requirement is due to all-liquid venting. Since this venting mode is                                       unlikely for a top venting ERS design, the homogeneous -vessel behavior offers the next most stringent                                 requirement and is therefore the recommended design approach for this configuration. Sizing based on all-                             vapor venting is both unrealistic and unsafe. J.C. Leung Fauske and Associates, Inc. AIChE Journal October                             1986

                        Note: Engineering Judgment should be used to match the extent of the relief protection effort to the                                        severity of the consequences. A risk assessment that considers both the consequences and likelihood of                                the over-pressure event can be used to assist in this engineering judgment. (Guidelines for Pressie Relief                                  and Effluent Handling 2nd Edition 2017)

                           i.       Determine & Acquire Resources Required to Eliminate Gaps

                                    a.      Code Requirements

                                             a.      ASME Code

                                    b.     Standards Required

                                             a.      DIERS Methodology (33-Mach II CDS)

                                             b.      OSHA 29 CFR 1910.119 (34-OSHA)

                                             c.      API 520/521 

                                             d.      NFPA 30

                                             e.      NFPA 58

                                             f.      API 2000

                                             g.     Compressed Gas Association Standard (CGA)

                                              f.    Corporate Relief Design Manual

                                    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.     OSHA 29CFR 1910.119

                                     b.     DIERS Methodology

                                     c.     ASME Code relevant sections

                                     d.     Compressed Gas Standard (CGA-S)

                                     e.     API 520/521 Relevant sections

                                     f.      NEPA 30

                                     g.     NEPA 58

                                     h.     API 2000

                                     i.     Guidelines for Pressure Relief and Effluent Handling

                                     j.     Corporate 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.        Retrial

               iii.   Software Evaluation

                                   a.       Mach II CDS, PSM Network System

                                              a.      Select Test Case (Evaluation & Training)

                                                       a.     Fire Case (35-Mach II CDS)

                                                       b.     DIERS Benchmarks  (36-CCPS)

                                                                a.     Liquids Case 8 (37-Mach II CDS)

                                                                b.     Vapors/ Gases  Case 1 (38-Mach II CDS)

                                                       c.      Perform two-phase flow evaluation  (39-Mach II CDS)

                                                                a.     DIERS Benchmarks  (40-Mach II CDS)

                                                                         i.      Two-phase flashing flow  (41-Mach II CDS)

                                                                        ii.      Hybrid flow (42- Mach II CDS)

                                                                       iii.      Frozen flow   (43-Mach II CDS)

                                                                       iv.      Churn-turbulent flow (44-Mach II CDS)

                                                                        v.      Homogeneous flow   (45-Mach II CDS)

                                                                       vi.      High viscosity flow (46-Mach II CDS)

                                                                b.     Two-phase test  (47-Mach II CDS)

                                                                c.      Coupling Equation   (48-Mach II CDS)

                                                                d.      Determine maximum fill to avoid two-phase

                                             b.      Compare software results

                                                       a.      Resolve differences

                                                                  a.     Contact DIERS

                                                                           a.     Discussed removal of entrance/exit & expansion losses

                                                                   b.     Contact i/ioMosaic about Super Chems software

                                                                           a.     Discuss why program give same results both for 4 inch and 6 inch 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 (49-CCPS)

                                                                           a.     William B. Hooper Monsanto Co.  Chemical Engineering November 7, 1989

                                                                  b.     The two-K method predicts (50-Monsanto Co)

                                                                            a.     William B. Hooper Monsanto Co.

                                                                  c.      Sensitivity of relief valves to inlet and outlet line lengths (51-Velicol Co.)

                                                                            a.     Brice A. Van Boskirk, Velsicol chemical Co. Chemical Engineering August                                                                                                1982

                 iv.    Determine Final Relief Design Methodology

      c.      Project Human Resource Management (52-PMP)

                 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 (53-CCPS)

                                         b.   Code Requirements  (54-CCPS)

                                         c.   Purpose of Hazop Reviews (55-CCPS)

                                        d.    Selection (56-CCPS)

                                        e.    Design  (57-CCPS) (88-CCPS)

                                        f.    Installation     (59-CCPS)

                                        g.    Maintenance (60-CCPS)

                      iii.      Manage Project Team

                                 i.       Hazop Review Kick off to Relief Design (61-CCPS)

                                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 (62-CCPS Approach to Design)

                                        a.     Calculate required capacity for each credible scenario (63-Mach II CDS Scenario Calculations)

                                        b.     Calculate required orifice size for each credible scenario (64- Mach II CDS -Orifice Sizing)

                                        c.      Select standard orifice size

                                        d.      Determine rate capacity of standard orifice

                                        e.      Perform inlet/outlet pressure drop calculations (65-Mach II CDS)

                                         f.      Ensure Code compliance (66-CCPS)

                                        g.      Select or verify adequacy of existing relief design

                                        h.      Create specification sheet

                                         i.      Make recommendations

                                         j.      Generate design record

                                        k.      Provide electronic storage of records

         d.     Project Communication Management (67-PMP)

                  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   (68-PMP)

                 i.      Conduct Procurement

                          i.     Equipment

                         ii.     Piping

                        iii.     Relief valves

                        iv.     Conservation vents

                         v.     Software

                        vi.    Services

        f.       Project Stakeholder Management  (69-PMP)

                   i.      Manage Stakeholder Engagement

                           i.     Determine needs

                          ii.     Proper Communication

                         iii.     Keep Informed

                         iv.    Meet Expectation

IV.      Monitor & Control Process Group  (70-PMP)

           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

                    Note: Engineering Judgment should be used to match the extent of the relief protection effort to the severity                        of the consequences. A risk assessment that considers both the consequences and likelihood of the over-                              pressure event can be used to assist in this engineering judgment. (Guidelines for Pressie Relief and Effluent                          Handling 2nd Edition 2017)

                     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