In a nutshell, Process Safety Management (PSM) is the prevention of unexpected and uncontrolled Loss of Containment (LoC) i.e. release of harmful substances, toxic or flammable, predominant consequences of which could be catastrophic failures and potential harmful events, like toxic releases, fires and explosions. Engineering expertise, decision making skills and management systems are used to achieve highest standards of PSM. Fundamentally, Process Safety is woven into the design and operation of the plant.
Incidents happen all over the process industry, it is no different than all other industries around the world. If not investigated properly and actions not implemented in time to stop the recurrence of unsafe incidents then disaster can’t be avoided. It is essential to eliminate the root causes, while addressing the immediate causes, to prevent the repeat event. A good incident investigation delivers improvement to safety performance and management systems.
At Petrotec, we have conducted numerous incident investigations and performed Root Cause Analysis (RCAs) for our clients. By the implementation of our recommendations, our clients have significantly reduced the process safety incidents on their sites. It has also increased the plant availability, decreased process disruptions and maintenance costs. Our consultants use the industry leading techniques and software’s to perform RCAs and generate reports while applying expert knowledge of processes and equipment.
Process Hazard analysis (PHA) is an essential tool for risk management of the facility as well as a legal and regulatory requirement.Anything which has potential to harm is called hazard. No industry exists without inherited hazards which can adversely affect people, equipment or environment. Process hazard analysis identifies plant hazards, assesses risks by considering the likelihood of the harmful event and the potential severity of the harmful event. PHA helps to decide if the additional controls are required to bring the risk to acceptable region or the existing control are sufficient. A good PHA not only determines the available controls but details their functionality and checks their adequacy for the hazardous scenarios too. Hazard identification (HAZID), Hazard and Operability Studies (HAZOP), Process Hazard Review (PHR) and Process Start up Safety review (PSSR) are well-known and broadly used techniques to perform PHAs.
Our team in trained and highly skilled in preparing and managing PHAs. We chair and also scribe all the techniques of PHAs. We also perform as an independent process engineer during studies.
As the risk surges towards intolerable region, the demand for more rigorous risk assessments and implementation of more robust controls becomes inevitable. Quantitative Risk Assessment (QRA) and good decision-making based on it is essential for managing high risk installations.
QRA is a combination of Physical Effects Modelling (PEM) and the frequency estimations of the undesirable, harmful events. In PEM, the harmful events (i.e. Dispersion of toxic and flammable materials, fires and explosions) and the Vulnerabilities of People, plant and environment are modelled. QRA not only determines the individual risks but also the societal risks.
At Petrotec, with our in-depth knowledge of plant systems and extensive experience, our specialists deliver very high quality QRAs and physical effects modelling to clients globally.
The installation of electrical and instrumentation equipment compliant to Hazardous Area Classification HAC zone significantly reduces the risk of onsite fires or explosions.
To carry out a Hazardous Area Classification HAC study and to document the conclusions, in form of Zones, is a specific legal requirement of The Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR).
The ideal combination of our engineering skills, knowledge of hazardous/flammable materials, know-how of of electrical & instrumentation equipment and CAD drafting skills have enabled us to generate best HAC zoning drawings and reports for existing and new facilities.
With the identification of new hazards on the existing plants, the use of Safety Instrumented Systems SIS are increasingly becoming inevitable. Whereas the functional safety is playing its vital role to protect the newly designed process systems from catastrophic failure, which can’t be achieved using conventional mechanical systems.
The expertise of our certified functional safety engineers covers Plant Functional Safety (PFS) ranging from carrying out the Layer of Protection Analysis (LOPA) to determine the Safety Integrity Level SIL for new and existing systems to the verification of the existing SIL loops. We can optimize proof test intervals to save maintenance costs and plant downtime.
The most efficient way to operate and sustain the plants is to build them inherently safe. Fundamentally safer designs result in less down time, increased availability, reduced maintenance costs and less operational disruptions.After the completion of construction phase, the cost of any modifications on the plant rises exponentially, often, more than ten time as compared to the initial cost during the design phase. To avoid this hefty cost, Inherent process safety assessments are recommended at the design stage of the Project to identify and correct the deficiencies. For the existing plants, inherent process safety can bring out the concealed hazards embedded within process systems, which can emerge unexpectedly resulting in harmful incidents. Our clients have largely benefited from the wide-ranging design and plant experience of the team at Petrotec, in assessment and implementation of inherent process safety to their Plants.
Petrotec delivers inherent process safety to clients during design phase and for the existing plants.
A well-designed plant will run safely and smoothly, while achieving the desired performance requirements. No operational issues will be observed during operation, the systems won’t shutdown spuriously and won’t require expensive plant modifications. Whereas, a badly design process results in operational nuisance, uncontrollable process, persistent demand on instrumented safety systems, lifting relief valves, failure of bursting discs and frequent maintenance shutdowns.Our engineers have delivered the new process designs and have verified the clients design too.We deliver the process design documents on time while meeting the company`s quality management standards. Our own QA/QC systems are world class.
The operational issues continue to rise with ageing of plant. Performance of plant equipment diminishes over time. Updated and new industry standards of construction and safety along with the requirement of production increase for plant sustainability require expansive modifications. To keep the licence to operate and comply with the legal requirements, the plant changes are unavoidable.
At Petrotec, the team have successfully delivered the optioneering, reverse engineering, trouble shooting, debottlenecking and production increase solutions to clients.