What are the common challenges and risks of setting and maintaining process safety operating limits?

Setting and maintaining process safety operating limits come with common challenges and risks: 1.Complexity:Ensuring limits align with diverse processes. 🔄 2.Accuracy:Setting limits that accurately reflect process conditions. 🎯 3.Complacency:Risk of overlooking updates or changes in operations. ⚠️ 4.Training:Ensuring all staff understand and adhere to limits. 📚 5.Monitoring:Continuous monitoring to detect deviations promptly.🕵️♂️ 6.Cost:Investment in technology and training for effective implementation.💰

In general the data needed to set the safe operating limits comes from design not the HAZOP. It is based on the size of the pipework (erosion etc), the composition of the fluid, the design standards associated with pressure containment and in the case of vessels the desire separation efficiency. It is the basis of your design communicated to variables which are measurable and then setting limits on those.

Common challenges and risks of setting and maintaining process safety operating limits include but not limited to: Defining accurate Limits: Operating limits are set based on comprehensive hazard analysis and reflect safe boundaries without compromising productivity. Human Factors: Human errors can lead to deviations from set limits. Equipment Variability: Equipment corrosion/malfunction can impact the ability to maintain operating limits. Dynamic Process Conditions: Changes in process conditions (process parameters) can quickly exceed set limits. MOC: Inadequate handling of changes to processes or equipment can introduce new risks. Maintaining limits requires constant monitoring, training, and periodic reviews.

Process parameters that deviate from the equipment's safe operating limit (SOL) are referred to as safe operating limit excursions (SOL). The following actions are advised in the event that the equipment design data are absent: - Employ a specialized third-party company to carry out the necessary tests, measurements, and inspections in accordance with certain standards, and to provide a comprehensive bundle of paperwork and certifications. - If the first option isn't feasible for any reason and the company has the resources and the staff it needs, the necessary recertification can be completed with the firm management's witnessing and approval. Forms and certifications should be signed to officially record the entire process.

Setting Process Safety Operating Limits (PSOLs) can be difficult due to a lack of data and knowledge about the process and its hazards. This lack of information could be caused by outdated or incomplete data, a lack of testing and validation, or poor communication and documentation. Without sufficient data and knowledge, it is challenging to determine the PSOLs needed to ensure the safety and efficiency of the process, and to identify potential deviations and consequences. To address this issue, it is crucial to conduct a thorough process hazard analysis (PHA), gather and update relevant data and information, and share and document this knowledge with all relevant parties.

Human factors and behavior play a crucial role in the implementation and maintenance of Process Safety Operating Limits (PSOLs). These factors encompass the psychological, social, and organizational aspects that influence how individuals interact with the process. They include perception, motivation, competence, and culture. On the other hand, human behavior refers to the actions and decisions people make in response to the process conditions, such as adhering to procedures, reporting issues, or taking shortcuts. The impact of human factors and behavior on PSOLs can be positive or negative, depending on how they align with the objectives and expectations of process safety.

Each company/business/facility shall have a system in place to address human factors at the design, construction and operational phases of a project. - Each shall assess human interactions with the facility as part of the design process. -Human factors analysis or (HFA) shall address computerized control systems that can confront operators with unmanageable amounts of information during an upset condition (alarm management). -HFA system shall examine the following: Alarm display. Information display. Ergonomics. - Each facility shall conduct task analyses to determine what can go wrong during a task, how it can be reversed through human recovery and, failing that, how the potential problem areas can be controlled.

Setting and maintaining Process Safety Operating Limits (PSOLs) can be challenging due to the influence of human factors and behavior on process performance and safety. Factors like perception, motivation, competence, and organizational culture can impact how individuals interact with the process, affecting adherence to PSOLs. To address this, organizations must prioritize training, foster a positive safety culture, and consistently reinforce compliance with PSOLs to mitigate risks associated with human behavior.

Effectively managing changes and uncertainties is crucial when establishing and sustaining (PSOLs). Changes encompass modifications in process parameters, equipment, materials, or environmental factors, ranging from wear and tear to external disturbances. Uncertainties involve variations and unknowns impacting process behavior, including measurement errors, model inaccuracies, or stochastic events. Such factors can render PSOLs outdated or ineffective, elevating the risk of process failure. To address this challenge, it is imperative to implement a robust (MOC) system, conduct regular audits and reviews, and employ adaptive and resilient PSOLs. Adhering to relevant codes and regulations ensures ongoing effectiveness and safety.

Setting and maintaining Process Safety Operating Limits (PSOLs) face a third challenge concerning the impact of changes and uncertainties on process stability and safety. Changes refer to modifications or deviations that occur in process parameters, equipment, materials, or the environment. They may include instances of wear and tear, corrosion, fouling, or external disturbances. Uncertainties, on the other hand, are variations or unknown factors that affect process behavior. These may stem from measurement errors, inaccuracies in modeling, or stochastic events. Both changes and uncertainties can render PSOLs outdated, inaccurate, or ineffective, thus increasing the risk of process failure or loss of control.

Indeed, companies need to stick to a change management procedure. Before starting any changes, company should assess the potential hazards associated based on the criticality of the change or process. This can be done by conducting a full PHA study or risk assessment & obtaining the necessary approvals. Creating a program for systematic asset integrity includes: - comprehensive performance standard (PS) for each system, including pressure relive systems, flare igniting systems, control and regulating systems, tanks and pressure vessels, etc. - As needs of the "fit for service" process, there should be predefined criteria, pass/fail characteristics, appropriate assurance tasks, frequencies for each & verification methods, inside the PS

Integration and coordination pose a fourth challenge when it comes to establishing and maintaining Process Safety Overpressure Layers (PSOLs). It is crucial to ensure that these PSOLs are interconnected with other process safety components and stakeholders. PSOLs are not standalone entities; they form an integral part of the larger Process Safety Management (PSM) system. This system includes various elements like risk assessment, emergency response, incident investigation, and continuous improvement. Moreover, PSOLs involve multiple stakeholders, such as operators, engineers, managers, regulators, and contractors, each with their own distinct roles, responsibilities, and interests in maintaining process safety.

Actually, SOL is strongly relied on asset/mechanical integrity pillar of PSM. It all begins with the Asset integrity activities such as: - Equipment certification in accordance with predefined performance criteria - Equipment inspection frequencies according to best practices and applicable manufacturer data as well as historical operating experience. - Keep records of every inspection and test that has been performed. The documentation process should include: - date of the test or inspection - name of the person who conducted the test or inspection - equipment serial number or other unique identifier - a description of the inspection that was conducted - test results

For organizations that rely on external suppliers or contractors, understanding and managing risks associated with the supply chain is crucial. Ensuring that suppliers adhere to similar safety standards and monitoring their processes can prevent unexpected safety breaches due to external factors.

Here are a few more things to think about. This is where you can share examples, stories, or insights that don't fit into any of the previous sections. Is there anything else you would like to add?

Design and operating limits need to be clear, explicit, documented and widely understood. Breach these on a regular basis, things go wrong very quickly. Statutory requirements to identify and assess these risks, document them, set performance requirements, maintain and monitor them, keep records, review, audit and improve. Normal practice to allow a margin of safety between operating envelope and such limits - alert and action limits set at some proportion of such limits. Documented alarm and trip limits within operating limits also registered. Leads to concept of layers of protection. These are not flexible, negotiable or based on opinion … they are hard limits which must be maintained rigorously.

Uma boa abordagem é correlacionar dados históricos e variáveis dinâmicas. Isso permite prever desvios antes de ocorrerem, automatizar alertas e ajustar limites adaptativos em sistemas críticos. Essa abordagem reduz a dependência de inspeções manuais, aumenta a proatividade e melhora a comunicação intersetorial, fundamentais na segurança de processos.