Process safety Boot Camp
Risk Based Process Safety
Manage Risk Element 8:
OPERATING PROCEDURES
Adapted from: [Link]
Overview
Standard Operating procedures are written instructions that list the steps
for a given task and describe the way the steps are to be performed.
Overview
SOP
Overview
SOPs
Incidents Related to SOPs
Texas City Refinery explosion
Fatalities (15)
Not Following Procedures
Occurred during startup after
Incidents Related to SOPs
Bayer CropScience Pesticide Waste Tank Explosion
Fatalities (2)
Outdated Procedures
Occurred During Startup after Major Changes
SOP, SWP and Maintenance Procedures
SOP SWP Maintenance Procedures
Converting raw Non-routine works not Maintenance and
materials to product involving processing or inspection work
maintenance
Why SOPs are important?
• Provide consistent information to all users
• Remove guesswork
Benefits of
SOPs
• Enhance employee performance
• Document and build upon your facility's experience
• Provide the tools for an effective training program
SOP System Framework
Maintain Dependable Practices
Identify SOPs needs
Develop procedures
Use SOPs to improve performance
Maintain SOPs
Maintaining Dependable Practices
Establish management system:
• Define authority to develop, change, and approve operating procedures,
• Define procedure development and change process,
• Define communications of SOPs to operator
Control documents format and content:
• Specify typical format for SOPs
• Specify minimum content for SOPs
• Ensure that all regulatory requirement regarding SOPs are implemented
Control documents:
• Controls should be in place to ensure that only current procedures are used.
Identifying SOPs Needs
Conduct Task Analysis:
Develop comprehensive list of the tasks people do (or are supposed to do) at the facility
Determine what SOPs are needed and the level of detail:
The level of detail needed in the procedures is a function of
(1) the risk associated with the task
(2) the knowledge, skills, and abilities of the person assigned to perform the task.
Address all operating modes:
• Such as normal operation, start-up and shutdown
Types of Operations
• Start-Up
▪ Initial Start-up/Commissioning
▪ Start-up after Turnaround
▪ Start-up after ESD
• Normal Operations
▪ Normal operations
- Including sampling and monitoring
• Shutdown
▪ Emergency Shutdowns
▪ Emergency Operations
▪ Normal Shutdowns
Develop the SOPs
• Use an appropriate format
• Address safe operating limits and consequences of deviation
• Address limiting conditions for operation
• Provide clear, concise instructions
• Supplement procedures with checklists
• Make effective use of pictures and diagrams
• Validate procedures and verify that actual practice conforms to
intended practice.
Operating Limit
• Required to include operating limits within
each SOP.
• Includes pressure, temperature, level, flow, concentration
and other.
• Refer to Process Safety Information (PSI) for safe operating
limits.
• Includes consequences of deviation from that limit and
actions required to correct or avoid deviation.
• Refer to Process Hazard Analysis (PHA) to specify deviations
and associated consequences.
• Consider creating Consequence of Deviation
Table
Consequence of Deviation Table
Examples of SOPs
Bad SOPs Good SOPs
Notes, Cautions, and Warning Statements
Use SOPs to improve performance
Use SOPs in Training
Hold organization accountable to follow procedures
Make the procedures available
Maintain SOPs
Manage Changes:
The SOPs shall be updated as part of MOC process while provide adequate training on the new
procedures.
Correct errors and omissions in a timely manner:
As operators spot errors or omissions, it is important that these be corrected in a timely manner.
Periodically review all operating procedures:
The appropriate time interval between reviews varies; but it typically ranges from 1 to 3 years,
assuming that in the mean time, the procedures are maintained under management of change
requirements.
KPIs
Suggested KPIs
• Number of audit findings related to SOPs
• Number of incident/deficiency report related to procedures.
• Number of changes to procedures not covered by MOC.
• The number of procedures that are past due for review.
Common finding during
the PSM gap analysis
Common Issues Related To SOP
No technical review
for the SOPs No a unified
No Element Owner operating
for the SOPs procedure
SOPs not covered all
modes of operation format
Operators are not
relying on the
SOPs if exist, they operating Checklists, figures,
are not used procedures and pictures are
not used
Wrap-Up
Wrap-Up
• Each group to discuss what they have learned about SOPs and make
presentation to other groups.
Thanks !!
