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1、Safety awareness sharing 工艺安全完整性管理 Process Safety Integrity Management (PSIM),一、背景，PSIM事故介绍二、什么是工艺安全？ 三、工艺安全完整性管理（PSIM）的目的四、怎样进行PSIM,PSIM的标准五、GDLNG怎样进行PSIM。六、回顾复习七、Sample、Q&A,培训内容,Purpose目的,To give you an appreciation of the importance of safety in the chemical industry and to show how DP LNG manage
2、s process safety.介绍工艺安全的重要性及DPLNG如何管理工艺安全,Background背景,The concept of managing industrial processes in a safe manner has been with us through the better part of the last century. However, during the late 1970s, 1980s and the early 1990s,起源于上世纪70年代an increase in the number and magnitude of catastroph
3、ic chemical, petrochemical and oil industry incidents resulted in an even greater emphasis on developing effective safety programs. 随着工业化的加速，灾难性的事故层出不穷,PSM Introduction,Since its beginnings at the turn of the century, the chemical industry has struggled to control the hazards inherent in the manufac
4、turing process.自 1900 年 前 后 起， 石油化 学 行 业 一 直 努 力 控 制 生 产 工 艺 中 的 危 险。,The 1947 Texas City Disaster 1947 年 得 克 萨 斯 灾 难,On April 16, 1947 the ship Grandcamp les-bain exploded in the Texas City harbor. Approximately 12 hours after the Grandcamp exploded a second ship, the High Flyer, caught fire and ex
5、ploded. The resulting explosions and fires caused widespread destruction of the surrounding manufacturing plants and community. This event, that occurred in 1947, is still the largest chemical disaster in U.S. history. The following are a few pictures of the devastation this disaster caused. 1947 年4
6、 月16 日，GRANDCAMP LESBAIN 轮 在 得 克 萨 斯 港 爆 炸。 约 12 小 时 后，“ 高 飞 者” 轮 因 之 着 火 爆 炸。 爆 炸 和 大 火 使 得 周 围 工 厂 和 社 区 大 面 积 毁 损。 这 起 事 故 至 今 仍 然 是 美 国 历 史 上 最 大 的 化 学 品 灾 难。,The picture shows the damage caused by the Texas City fire of 1947 and the remains of the Monsanto plant. Seventy -two employees died ins
7、tantly and ninety -five were still missing a week later. Twenty-two of the twenty-four chemists that monitored production were killed in the explosion. Please note the locations of the two ships. The Grandcamp that caused the initial explosion and fire and the High Flyer which exploded later due to
8、burning sulfur in a cargo hold.工 厂 的72 位 雇 员 当 场 死 亡、95 位 一 周 后 仍 然 下 落 不 明。 24 位 化 学 师 中， 当 时 正 在 监 控 生 产 的 22 位 在 爆 炸 中 丧 生。 请 注 意 两 条 轮 船 的 位 置。,Bhopal, India 印 度 泊 帕 尔,December 3, 1984A leak of 200 tons of methyl isocyanate at Union Carbides facility in Bhopal killed an estimated 2,000 people an
9、d injured as many as 100,000 others. 1984 年 12 月 3 日 联 合 碳 化 物 厂 200 吨 异 氰 酸 甲 酯 溢 漏， 估 计 有 2,000 人 丧 生、 另 有 100,000 人 受 伤。,Flixborough(England),On June 1, 1974 a vapor cloud explosion destroyed the Nypro cyclohexane oxidation plant at Flixborough, England killing 28 people. Other plants on the site
10、 were seriously damaged or destroyed and the site presented a scene of utter devastation. The accident was traced to a poorly qualified design team that were asked to design and install temporary piping.,Shiw:英格兰-环己胺爆炸，死亡28人，爆炸原因：设计不当,Piper Alpha,Shiw:The Piper Alpha was a North Sea oil production p
11、latform，死亡167人,BP America Refinery ExplosionTexas City, TX, March 23, 2005,Burnt vehicles and debris left by hydrocarbon vapor explosions that killed 15 workers at the BP Texas City refinery March 23.,Lesson Learning from incidents从事故中吸取教训,这些事故为什么会发生？Why did it occurse?工艺设计不合理 Designed issue项目建设有缺陷
12、Defectiveness of project construction 人员的操作不规范 Did not follow the procedure设备本体有缺陷Defectiveness of Equipments设备维护保养不适当 Improper Equipment Maintenance-e.g,PURPOSE OF PSMPURPOSE OF PSM工艺安全管理（PSM）的目的,Prevention, or minimization of the consequences, of catastrophic releases of toxic, reactive, flammable
13、, or explosive chemicals预防，或最小化具有毒性、反应性、易燃性或爆炸性的化学品释放产生的灾难性后果 Employee safety (OSHA) 职工安全（OSHA) Public and the environmental (EPA) 公众与环境（EPA） Standard is to help prevent or mitigate episodic chemical releases that could lead to a catastrophe 标准有助于预防或缓和化学物质释放事件可能导致的灾难性后果,REGULATIONS规定,OSHAs PSM Regul
14、ation, 29 CFR 1910.119 OSHA发布的工艺安全管理规定 （职业安全与卫生管理局） Became effective5/26/921992年5月26日起生效Immediate compliance was required for all but PHA除工艺危害分析外，对其他方面都做了要求 EPAs RMP Regulation, 40 CFR Part 68 EPA发布的风险管理计划（RMP）规章（美国国家环境保护局）（EPA） Became effective 6/20/961996年6月20日起生效 Provided a three-year period to c
15、omply要求遵守三年,Catastrophic release means a major uncontrolled emission, fire, or explosion involving one or more highly hazardous chemicals, that presents serious danger to:灾难性释放指一种或多种高度危险的化学品所引发的不受控制的重大排放事故、火灾或爆炸事故，严重危害: Employees in the workplace工作场所的职工 Members of the public群众 Environment环境 Source:
16、29 CFR1910.119,Public receptor means:公共接受者指： Offsite residences 厂区外住宅 Institutions (e.g. schools, hospitals) 机构（例如学校、医院） Industrial, commercial, and office buildings 工业、商业和办公大楼 Parks, or recreational areas inhabited or occupied by the public 公众聚集的公园或休闲场所Environmental receptor means环境接受者指 Natural are
17、as such as national or state parks, forests, or monuments自然风景区，比如国家公园、森林或纪念性建筑物 Officially designated wildlife sanctuaries, preserves, refuges, or areas官方指定的野生动物保护区、禁猎区等 National wilderness areas国家自然保护区,The proactive identification, evaluation and mitigation or prevention of chemical releases对化学品释放事
18、先进行鉴定、评价、缓和或预防 That could occur as a result of failures in process, procedures or equipment工艺、规程或设备出现故障时可能发生Source: OSHA Publication 3133, Process Safety Management Guidelines for Compliance.,IntroductionToProcess Safety & Process Safety Integrity Management工艺安全与工艺安全完整性管理引言,When Process Goes Wrong.当
19、工艺发生异常时,Introduction to ProcessSafety Management, PSM:,WHY? Major chemical incidents in the 70s and 80s:Flixborough (UK 1974, VCE 28 killed)Seveso (Italy 1976, reaction runaway)Bhopal (India 1984, chemical release 2,000 to 14,400 killed)Piper Alpha (North Sea 1988, Hydrocarbon gas ignition, 167 kill
20、ed),工艺安全管理（PSM）引言,WHY? 为什么？ 70年代和80年代发生的重大化学事故Flixborough （英国，1974年，蒸气云爆炸（VCE）， 28人死亡）Seveso （意大利，1976年，反应失控） Bhopal （印度，1984年，化学物质释放， 2000至14400人死亡） Piper Alpha （北海，1988年，碳氢化合物气体着火， 167人死亡）,Do you handle materials and conduct operations with fatality potential?您是否有接触存在致命性风险的材料和作业？,Recent world indu
21、stry fatalities have involved:与世界最近发生的工业事故有关： Natural gas 天然气 Flammable solvents 易燃溶剂 Combustible dusts 可燃粉尘 Failed permit to work system 失效的工作许可证系统,Handled at your facilities?您的设施是否有接触这些物质?,我们所运行的系统就是天然气行业，而且我们公司的安全承诺是：零事故、零伤害、零损害环境，所以： . 大家知道我们所从事的岗位有多重要？ . 大家知道自己的职责是什么，你所从事的岗位需要什么样的能力？.其实我们日常进行的项
22、目从开始设计-安装-运行-维护，都在做这个系统的工作了，我们怎样把它当成一个系统呢？,What is Process Safety?什么是工艺安全？,Process Safety,Chemical industry term for “system safety” in a more broad technology contextFocus on the safety of the technology of chemical manufacture“Personal safety”, “industrial safety”, “workplace safety” still importa
23、ntBut, the activities to manage these risks are very differentGood personal safety performance does not ensure good process safety performance,工艺安全,“系统安全” 在化工行业这一更为广阔的技术背景下的定义 主要是化学生产技术的安全“个人安全”、“工业安全”、“工作场所安全”也很重要但是，这些风险的管理工作非常不一样个人安全做得好并不能保证工艺安全也做得很好,Workplace Safety工作场所安全,Slips, trips, falls, mov
24、ing equipment, “struck by” accidents, etc.滑倒、绊倒、摔倒、移动设备，“撞击”事故，等 These are important, and must not be neglected这些极为重要，不可忽视 Prevention activities may be very different from process safety management systems预防工作可能与工艺安全管理系统大不相同,Personal Safety Management个人安全管理,Hazard recognition by workers工人对危害的认知 Many
25、 of the hazards are such that they can be readily recognized without specialized knowledge and expertise不少危害都可以轻易识别出来，不需要借助专业的知识 Personal protective equipment个人防护装置Procedures and training程序和培训 “Behavior based safety” programs“行为安全”程序,Chemical Process Safety化学工艺安全,Major incidents involving the releas
26、e of hazardous materials or energy有害物质或能量释放可能导致的主要事故 Consequences can be safety (fires, explosions, toxic material exposure), environmental damage, or major economic losses后果可能是安全（火灾、爆炸、毒性物质曝露）、环境破坏或重大经济损失,Chemical Process Safety化学工艺安全,Incidents can have catastrophic impacts事故可能导致灾难性后果 Multiple inju
27、ries or fatalities大量的伤害或死亡事故 Major economic, property, environmental, and corporate image damage重大经济、财产损失和环境、公司形象破坏 Impact public outside facilities冲击外部公众设施,Chemical Process Safety化学工艺安全,Prevention预防Design and engineering of facilities设施设计与工程 Design to minimize human error, make equipment error tole
28、rant设计的目标是将人为误差降至最低、使设备导致的错误在可容忍的范围内Mechanical integrity and maintenance机械完整性和维护Control, training, procedures, hazard identification, management of change, technical risk management.控制、培训、程序、危害识别、变更管理、技术风险管理,Hazard Recognition Personal Safety Compared to Process Safety危害认知个人安全与工艺安全比较,Personal safety
29、个人安全 Working at elevation, slipping and tripping hazards, moving equipment hazards 从事的工作涉及提升、滑倒和摔倒风险、移动设备 风险 Do not require special knowledge to recognize不需要专业知识就可觉察到 But does require training and awareness to understand significance and take required actions但仍需要培训，应充分认识到重要性并采取必要的措施,Hazard Recogniti
30、on Personal Safety Compared to Process Safety危害认知人身安全与工艺安全比较,Process safety工艺安全 Reactivity hazards, equipment overpressure hazards, flammability, toxicity, etc.反应性危险、设备超压危害、可燃性、毒性，等等 Requires specialized knowledge and training需要专业知识和培训 In some cases the knowledge may be beyond what can realistically
31、 be expected from non-technical personnel在某些情况下，非技术人员不可能具备某些知识,Hazard Recognition Personal Safety Compared to Process Safety危害认知人身安全与工艺安全比较,Process safety工艺安全 For example is the relief valve on the reactor big enough to protect against a runaway reaction? Is the emergency relief collection and treat
32、ment system designed adequately to prevent generation of a flammable gas cloud at a location where ignition is possible? Is the emergency relief discharge system adequate to prevent exposure of personnel to hazardous vapor concentrations?例如反应器上的安全阀是否足以抵抗失控反应？应急避难搜集和处理系统是否设计得当，能够防止可燃气云在有着火隐患的地方产生？应急减
33、压排气系统是否能够使人员免于暴露在危险的蒸气浓度中？,How is Process Safety Addressed?有关工艺安全的说法,Engineering Design Practices and Standards工程设计实践与标准 Management Systems管理系统 Procedures (R&D, Engineering, Design, Construction, Startup, Operating, Maintenance, Change, etc.)程序（研发、工程、设计、施工、启动、操作、维护、变更，等等） Safety reviews安全检查 Operatin
34、g Procedures操作规程,How well an organization does these procedures and practices defines its process safety culture,Management Systems管理系统 Training 培训 Equipment Inspections/ Mechanical Integrity设备检查机械完整性 Contractor process safety program承包商工艺安全程序 Near Miss/ Incident Investigations侥幸事故事故调查 Performance M
35、anagement / Goals业绩管理目标 Audits/ Site inspections审核/现场调查,一个组织机构开展这些规程和实践的情况可以体现它的工艺安全文化,Process Safety V/s Process Safety Integrity Management工艺安全 V/s 工艺安全完整性管理,Process Safety Issues: A formal review that identifies process hazards relative to established standards; for example, examining plant and e
36、quipment. e.g. Absence of a safety relief valve while inspecting a pipeline or an equipment Process safety issues are specific and will vary from plant to plant It addresses the presence of a particular hazard at a particular time and can lead to a correction without addressing the underlying cause工
37、艺安全问题： 根据相关标准，进行正式程序来识别工艺危害，例如，审查工厂和设备。 例如，在检查管道或设备时发现没有配备安全阀各个工厂存在的工艺安全问题各不相同注意到在某个时刻存在的某种风险，可能导致没有考虑根本原因就进行 修正,Process Safety Integrity Management (PSIM) Issues: A systematic review of the PSIM systems, used to verify the suitability of these systems and their effective, consistent application.e.g
38、 .Ensuring that the safety relief valve is designed, installed, operated and maintained as per the standardsThe PSIM systems are the same irrespective of the plantDetects the breakdown in the system and addresses the root cause工艺安全完整性管理（PSIM）问题： 对工艺安全完整性管理（PSIM）系统进行系统性检查，一般是检验这些系统的适用性及其有效性而和一致性的行为。
39、例如，保证根据标准来设计、安装、操作和维护安全阀 不管装置如何，工艺安全完整性管理（PSIM）系统都是一样 检测系统故障，并找出根本原因,All Elements will be grouped in three main segments:在 确 保 生 产 工 艺 安 全 方 面， 全部 要 素 相 互 依 存，可 归 纳 成 三 组：1) TECHNOLOGY 工艺技术2) PERSONNEL 人员3) FACILITIES 设施,ELEMENTS OF OSHAS PSMPROGRAMOSHA工艺安全管理项目的要素,Employee ParticipationProcess Safet
40、y InformationProcess Hazard AnalysisOperating ProceduresTrainingContractorsPre-Startup Safety ReviewMechanical IntegrityHot Work PermitManagement of ChangeIncident InvestigationEmergency Planning and ResponseCompliance AuditsTrade Secrets,职工参与工艺安全信息工艺危害分析操作规程培训承包商启动前安全检查机械完整性动火作业许可证变更管理事故调查应急计划与反应合规
41、性审核商业秘密,“BP PSIM标准”要求遵循的10个要素：BP 10 Elements of The PSIM Standard :责任Accountabilities能力Competence危害评价和风险管理Hazard Evaluation and Risk Management设施和工艺完整性Facilities and Process Integrity防护系统Protective Systems通则和程序Practices and Procedures变更管理Management of Change应急响应Emergency Response事故调查和教训吸取Incident In
42、vestigation and Learning业绩管理和改进Performance Management and Learning.,职工参与工艺安全信息工艺危害分析操作规程培训承包商启动前安全检查机械完整性动火作业许可证变更管理事故调查应急计划与反应合规性审核商业秘密（我们不涉及）,责任能力危害评价和风险管理设施和工艺完整性防护系统通则和程序变更管理应急响应事故调查和教训吸取业绩管理和改进,北美OSHA工艺安全管理项目的要素和GDLNG 采用的BP PSIM 要素的对比,Overview of PSIM standard to IM standardBP 的工艺安全完整性管理发展到完整性管
43、理 （版本对比）,Integrity Management Standard 2006,Process Safety Integrity Management Standard 2001,Overview of PSIM standardPSIM 标准总的概览,DPLNG的目的是通过“工艺安全完整性管理标准”的实施，减少因油气和化学品失控释放造成重大事故的可能性。其中包括这些物质灾难性和慢性释放进入大气、水体或地面。防止设备/基础设施失效从而严重危害人身、环境和业务运营。Through the implementation of the PSIM Standard, DPLNG aims to
44、 reduce the possibility of Major Accidents caused by the uncontrolled release of hydrocarbons and chemicals. This includes catastrophic and chronic releases to the atmosphere, water or ground and the prevention of equipment/infrastructure failure that could lead to serious harm to people, the enviro
45、nment and business operations.,危害评估和风险管理,制定风险管理计划,学习和提高,执行风险管理计划,完整性管理程序,关键行动,标准的要素,指定IM的责任人系统的识别主要的危害评估设备的危险程度定义安全的操作,定义通则和程序识别所需要的IM能力建立设备风险基础的IM计划制定腐蚀管理计划建立应急响应计划,进行设备的完整性管理计划检验应急响应计划变更管理,事故调查业绩管理根据KPI作出评估审计和同等的检查,1，3,2，4，5，6，8,4，5，7，8,9，10,Safety is good for business,lupy1:安全是企业发展的基石和催化剂,为什么要工艺安
46、全完整性管理？Why PSIM?,它至关重要的目的是消除不受控制的泄放以及防止设备和装置的失效故障 The overriding objectives are to eliminate uncontrolled releases and prevent equipment or infrastructure failures.,工艺安全完整性管理的重大事故常常危及人员、环境和业务运营。大鹏公司的目的是在“工艺安全完整性管理”方面采用统一的方法来避免这类事件发生。Major Process Safety Integrity management incidents are damaging to
47、 people, the environment and business operation. DPLNG aims to employ a consistent approach to Process safety integrity Management to avoid such incidents.本“标准”的目的是确保DPLNG从设计、建设、运行、维护到退役的整个运行寿命周期拥有正规的方法进行完整性管理。The intent of this Standard is to ensure there is a formal approach to total life cycle in
48、tegrity of DPLNG Operations through design, construction, operation, maintenance and decommissioning.,DPLNG的目的是通过“工艺安全完整性管理标准”的实施，减少因油气和化学品失控释放造成重大事故的可能性。其中包括这些物质灾难性和慢性释放进入大气、水体或地面。防止设备/基础设施失效从而严重危害人身、环境和业务运营。Through the implementation of the PSIM Standard, DPLNG aims to reduce the possibility of Ma
49、jor Accidents caused by the uncontrolled release of hydrocarbons and chemicals. This includes catastrophic and chronic releases to the atmosphere, water or ground and the prevention of equipment/infrastructure failure that could lead to serious harm to people, the environment and business operations
50、.,什么是PSIM标准？What is PSIM Standard?,PSIM工艺安全完整性管理 Process Safety Integrity Management工艺安全完整性管理标准是一个实用的标准（如同驾车标准和工作控制标准）。它描述了为保证DPLNG（接收站和管线）设备装置的物理完整性和运营可靠性所需的职责、程序和准则。The PSIM Standard is a functional standard (like Driving Standard and Control of Work Standard) that outlines accountabilities, proce
