Inherently Safer Design (engineering Design Guideline)

KLM Technology Group
Practical Engineering Guidelines for
Processing Plant Solutions
KLM Technology Group #03-12 Block Aronia, Jalan Sri Perkasa 2 Taman Tampoi Utama 81200 Johor Bahru Malaysia

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Kolmetz Handbook of Process Equipment Design
SAFETY IN PROCESS EQUIPMENT DESIGN

Page : 1 of 140
Rev: 03 Rev 01 July 2011 Rev 02 Aug 2014 Rev 03 Dec 2014
Co Author
Rev 01 Aprilia Jaya Rev 02 Yulis Sutianingsih Rev 03 Aprilia Jaya
Editor / Author
Karl Kolmetz

INHERENTLY SAFER DESIGN

(ENGINEERING DESIGN GUIDELINE)

KLM Technology Group has developed; 1) Process Engineering Equipment Design Guidelines, 2) Equipment Design Software, 3) Project Engineering Standards and Specifications, and 4) Unit Operations Manuals. Each has many hours of engineering development.
KLM is providing the introduction to this guideline for free on the internet. Please go to our website to order the complete document.
www.klmtechgroup.com

KLM Technology Group
Practical Engineering Guidelines for Processing Plant
Solutions

Kolmetz Handbook of Process Equipment Design
Safety in Process Equipment Design
(ENGINEERING DESIGN GUIDELINES)

Page 2 of 140 Rev: 03 December 2014

TABLE OF CONTENT

INTRODUCTION

5

Scope

5

General Design Considerations

6

A. Safety Requirements

11

B. Safety Program

10

C. Engineering Ethics

13

D. Statistics

14

E. Acceptable Risk & Public Perceptions

18

F. Hazard and Operability Analysis (HAZOP)

18

G. Material Hazard

22

H. Fire and Gas Protection

26

I. Inherent Safety

32

DEFINITIONS

35

THEORY

38

Safety Studies

39

The Design Process

41

Site Selection

46

Plant and Unit Layout

49

KLM Technology Group
Practical Engineering Guidelines for Processing Plant
Solutions

Kolmetz Handbook of Process Equipment Design
Safety in Process Equipment Design
(ENGINEERING DESIGN GUIDELINES)

Page 3 of 140 Rev: 03 December 2014

Storage Tank

63

Distillation

67

Reactors

71

Heat Transfer System

74

Piping System

77

Flare

83

Pressure Relief Systems and Specifying Valves to Increase Safety

89

An Electrical Area Classification

93

Inherently Safer Design

94

A. Key Elements

94

B. History

94

C. Basic Concept

97

D. Chemical Process Safety Strategies

98

E. Inherently Safer Design Processes

100

F. ISD in the Process Design Life Cycle

104

G. Transportation

107

H. Human Factors

108

I. Concerns

112

J. ISD Implementation

113

K. The Myths

114

L. Conceptual ISD in Plant

115

KLM Technology Group
Practical Engineering Guidelines for Processing Plant
Solutions

Kolmetz Handbook of Process Equipment Design
Safety in Process Equipment Design
(ENGINEERING DESIGN GUIDELINES)

Page 4 of 140 Rev: 03 December 2014

Emergency Shut Down (ESD)

119

Hazard Identification Methods Summary

124

APPLICATION

126

REFERENCES

134

LIST OF TABLE

Table 2 : Accident Statistics

16

Table 3 : FAR Statistics

17

Table 4 : Guide Words for HAZOPS Studies

19

Table 5 : Typical material characteristic

24

Table 6 : Recommended velocities for commonly service

82

Table 7 : Zone Classification

93

Table 8 : Inherently Safety Techniques

101

Table 9 : The conceptual design phase opportunities

115

Table 10: Efforts aimed at creating less hazardous conditions may be effective.

116

Table 11: look for ays to simplify complex designs during the detailed design phase 117

Table 12 : human factors should be re-examined during the procurement / construction

phase

118

KLM Technology Group
Practical Engineering Guidelines for Processing Plant
Solutions

Kolmetz Handbook of Process Equipment Design
Safety in Process Equipment Design
(ENGINEERING DESIGN GUIDELINES)

Page 5 of 140 Rev: 03 December 2014

LIST OF FIGURE

Figure 1 : Causes of losses in the largest hydrocarbon-chemical plant accidents

9

Figure 2 : Hardware associated with largest losses

9

Figure 3 : Ingredients for successful safety prgoram

12

Figure 4 : HAZOP Proceudre Illustration

21

Figure 5 : Failure in Safety Management

32

Figure 6 : Causes of Control System Incidents

43

Figure 7 : Inherent safety review preparation

45

Figure 8 : Inherent safety review

46

Figure 9 : Typical plant Layout

60

Figure 10 : Type of storage tank : (a) Sphere, (b) Cylinder

67

Figure 11 : Layout of Distillation

70

Figure 12 : Simplicity chemical reactor

73

Figure 13 : Heat transfer system in heat exchanger

77

Figure 14 : Layout of piping system

83

Figure 15 : Steam Assisted Elevated Flared System

88

Figure 16 : Pressure Relief Valve

91

Figure 17 : Traditional Risk Management

96

Figure 18 : Chemical Process Safety Strategies

99

Figure 19 : Inherently Safer Design in the Process Design Life Cycle

106

Figure 20 : Illustration of Never Exceed Limits

111

Figure 21 : ISD Implementation

113

Figure 22 : Emergency shut down (ESD) principle hierarchy

123

Figure 23 : Seveso Reactor

105

KLM Technology Group
Practical Engineering Guidelines for Processing Plant
Solutions

Kolmetz Handbook of Process Equipment Design
Safety in Process Equipment Design
(ENGINEERING DESIGN GUIDELINES)

Page 6 of 140 Rev: 03 December 2014

INTRODUCTION
Scope
This design guideline covers safety issues in process equipment design including chemical, petrochemical, and hydrocarbon processing facilities. It assist personnel to understand the basic concepts of process safety and increase the knowledge of prevention and reduce the incidents that might happen.
The design consideration discussed is methods of safety; 1. Inherently safer design, 2. Hazard and Operability Analysis (HAZOP) 3. material hazards and 4. fire protection. Reviewed are plant and unit layout, equipment spacing and some equipment which in which incidents might happen such as storage tank, distillation, reactors, piping system, flare and piping system.
It is clear that choices made early in design can reduce the possibility for large releases and may reduce the effects of releases. One should consider the variety of mitigation measures to reduce the severity of the effects of a release,

KLM Technology Group
Practical Engineering Guidelines for Processing Plant
Solutions

Kolmetz Handbook of Process Equipment Design
Safety in Process Equipment Design
(ENGINEERING DESIGN GUIDELINES)

Page 7 of 140 Rev: 03 December 2014

General Design Considerations
The comparison of the safety of equipment is not straightforward. It depends on several features of both process and equipment themselves. It can be evaluated from quantitative accident and failure data and from engineering practice and recommendations.
Unit operations may include physical operations and further processing or preparation for further reactions or for shipment. These operations include mixing or separating, size reduction or enlargement, and heat transfer. General hazards in physical operations are:
1. Vaporization and diffusion of flammable liquids and gases 2. Spraying or misting of flammable liquids 3. Dispersion of combustible dusts 4. Mixing highly reactive chemicals 5. Increase in the temperature of unstable chemicals 6. Friction or shock of unstable chemicals 7. Pressure increase in vessels 8. Loss of inertants or diluents
Some of the safety elements that can be included on the flow sheets are:
1. Process materials properties 2. Process conditions (pressure, temperature, composition) 3. Inventory 4. Emergency and waste releases 5. Process control philosophy

KLM Technology Group
Practical Engineering Guidelines for Processing Plant
Solutions

Kolmetz Handbook of Process Equipment Design
Safety in Process Equipment Design
(ENGINEERING DESIGN GUIDELINES)

Page 8 of 140 Rev: 03 December 2014

When considering the design aspects of a project, it can be identified three approaches to fault management that are of particular importance:
1. System Architecture The system architecture has an enormous effect on the ability of a system to tolerate faults within it. It can provide some protection against random component failure and some forms of systematic fault. It does not usually tackle the problems associated with specification faults.
2. Reliability Engineering. This is primarily concerned with the susceptibility of a system to random hardware component failures. However, some engineers believe that these techniques may also be applied to some systematic faults.
3. Quality Management Considerations of quality cover all aspects of a system’s life and are therefore of great importance to fault management.
In addition, good plant operating practice would include
1. Written instruction in the use of the hazardous substances and the risks involved. 2. Adequate training of personnel. 3. Provision of protective clothing and equipment. 4. Good housekeeping and personal hygiene. 5. Monitoring of the environment to check exposure levels. Consider the installation of
permanent instruments fitted with alarms. 6. Regular medical checkups on employees, to check for the chronic effects of toxic
materials. 7. Training of local emergency response personnel.

KLM Technology Group
Practical Engineering Guidelines for Processing Plant
Solutions

Kolmetz Handbook of Process Equipment Design
Safety in Process Equipment Design
(ENGINEERING DESIGN GUIDELINES)

Page 9 of 140 Rev: 03 December 2014

Certain types of processes, process conditions, or fluids handled introduce factors which affect the safety of the plant. These factors must be taken into consideration in the design. They include:
1. High-severity operating conditions, e.g., extremes of temperature or pressure.
2. Batch or cyclic processes or processes undergoing frequent startup and shutdown, where the opportunities for operating error are greater than normal.
3. Processes subject to frequent upsets by integration with other plants or where dangerous conditions may arise from utility failures.
4. Unstable processes, in which decompositions, temperature runaways, or other unstable reactions are possible
5. Fluid solids processes, in which stable and safe operations depend on the effectiveness of fluidization of solids to prevent reverse flow, e.g., catalytic cracking.
6. Fluid properties and characteristics such as flammability, vapor pressure, autorefrigeration, corrosion, erosion, toxicity, and chemical reactivity, including the variations in these properties which may occur at abnormal operating conditions.
7. Start up or shut down is an infrequent activity. Therefore, startup and emergency/normal shutdown procedures must be as simple and logical as possible. This must be incorporated into design considerations.
8. High noise evolution may pose communications problems and impair operator performance by creating additional stress.
Figure 1 presents the causes of losses for the largest chemical accidents. By far the largest cause of loss in a chemical plant is due to mechanical failure. Failures of this type are usually due to a problem with maintenance. Pumps, valves, and control equipment will fail if not properly maintained.
The second largest cause is operator error. For example, valves are not opened or closed in the proper sequence or reactants are not charged to a reactor in the correct order. Process upsets caused by, for example, power or cooling water failures account for 11% of the losses. While figure 1 presents a survey of the type of hardware associated with large accidents.

KLM Technology Group
Practical Engineering Guidelines for Processing Plant
Solutions

Kolmetz Handbook of Process Equipment Design
Safety in Process Equipment Design
(ENGINEERING DESIGN GUIDELINES)

Page 10 of 140 Rev: 03 December 2014

Figure 1: Causes of losses in the largest hydrocarbon-chemical plant accidents (13) Figure 2 : Hardware associated with largest losses (13)