Index A Accessibility electronic 40 105 of emergency operating procedures 85 of procedures 15 32 Accidental chemical release xiii Administrative procedures xiii 27 Alignment 75 American Petroleum Institute 3 16 common points with OSHA and EPA 119 Recommended Practice 750 4 13 115 Assessing training nereds 122 Audience 3 B Batch processing 56 Branching xiii 52 62 C Center for Chemical Process Safety (AIChE) 1 3 4 11 16 17 81 Guidelines for Technical Management of Chemical Process Safety 4 11 Plant Guidelines for Technical Management of Chemical Process Safety 115 141
142 Checklists design checklist 25 58 elements 58 for determining which procedures must be written 29 122 procedure drafting 54 procedure evaluation criteria 58 127 readability 88 reference section of procedures 43 for writing EOPs 83 Chemical Manufacturers Association 3 4 Responsible Care 4 12 115 Clarity of procedures 15 36 68 Contingencies, identifying 71 Conditions or criteria 72 Conditional instructions 72 Consensus codes 16 115 Control of procedures 15 97 see also Procedure management system Controls 80 Criteria, procedure, checklist 127 Current practices, evaluating 24 34 D Design checklist 25 of a procedure management system 21 system specification 43 technical and safety information 33 Directions, emergency, giving clear 88
Drafting procedures 54 cost 110 143 E Ease of reading EOPs 88 Effective procedure writing elements of 15 introduction to 1 return on investment 113 Electronic display and document control 105 of emergency operating procedures 90 of hard-copy procedures 40 Emergency operating procedure(s) (EOP) xiii 6 76 79 access to 85 assigning specific responsibilities 95 availability 90 defining events requiring 79 developing and writing 82 ease of reading 88 example 95 giving clear directions 88 incorporating human factors 87 information to include 84 physical indicators 91 using decision aids 92 94 Emergency response plan xiii Emergency situations, identifying 81 Employee input 17 35 Engineering procedures 5 28
144 Environmental Protection Agency (EPA) 16 common points with API and OSHA 119 Rule 40 CFR Part 68 3 4 13 108 117 Equipment 80 Evaluation criteria elements of, checklist 58 importance of 57 users of 58 66 Event xiii 79 Examples branching 53 63 calculations 74 cautions, warnings, notes 65 66 conditional instructions 73 decision table 93 emergency operating flow chart 94 emergency operating procedure 76 86 89 95 follow up action 77 graphs 74 identifying conditions or criteria 72 identifying contingencies 71 identifying end of a procedure 60 page layout 38 posted written procedure 90 precautions 44 prerequisites 46 procedure control information 60 99 procedure formats 130 procedure layout 42 procedure request form 100
145 Examples (Continued) procedure titles 59 purpose section 41 61 quantitative terms 71 questions in a procedure 93 quick reference card 91 references 64 sequence 70 signoff lines 68 131 133 specifying responsibility 67 95 steps 69 temporary procedure 61 T-format 39 40 valve alignments 75 visual indicators 87 Existing procedures 24 34 43 see also Current practices F Federal Emergency Management Agency (FEMA) 115 Flow charts job and task 28 sample emergency operating 94 procedure control 99 Follow up actions 76 G Governmental regulations 13 see also specific agency, association, or regulation
146 Guidelines and regulations, see also specific agency, association, or rule understanding 9 voluntary 10 H Human factors xiii 34 54 in emergency operating procedures 87 special qualifications 77 physical indicators of emergencies 91 Human resources 34 66 identifying 26 I Institution of Chemical Engineers 3 116 Instrumentation 80 International Organization for Standardization (ISO) 4 14 16 116 ISO 9000 4 116 ISO Standard 9002 14 J Job and task analyses 43 flow chart 28 Job safety analyses 43 123 M Maintence procedures xiv 28 Management 5 of change xiv 6 17
Material Safety Data Sheets (MSDS) 43 147 O Objectives, book 2 Occupational Safety and Health Administration (OSHA) 11 13 117 common points with EPA and API 119 Rule 29 CFR 1910.119 3 17 29 104 Official Journal of the European Communities 4 116 Operating equipment, parameters, ranges, and limits 34 70 136 Operating limits inclusion in procedures 18 70 sample tables 136 Operating procedures xiv 28 Operations and maintenance 5 Organization for Economic Cooperation and Development (OECD) 4 116 Organization Resources Counselors (ORC) 11 116 Organizations and documents recommending or requiring procedures 4 P Page formats 34 37 Performance evaluation 124 Piping and instrumentation diagrams (P&IDs) 43 Placards or posted written procedures emergency operating procedures 90 Precautions 44 Prerequisites section 45 Procedure approval 102
148 Procedure control 15 17 97 purpose 97 definition 97 of revisions and development 98 of review 101 Procedure criteria checklist 127 Procedure development benefits 21 107 costs 108 employee input 17 35 important points to be addressed 12 outline for 22 reasons for 1 107 Procedure elements, common regulations, and consensus codes, list 16 Procedure format 37 control information 59 and electronic access 40 105 identifier, unique 61 last page identifier 60 page layout 34 36 37 samples 130 T-format 39 Procedure management system 15 costs 109 defined xiii design checklist 25 58 designing 21 determining requirements 24 drafting a procedure 54 110
149 Procedure management system (Continued) elements of 15 18 22 evaluating current 24 34 failure of, reasons for 31 identifying resources 26 implementing 26 30 111 maintaining and improving 31 review and approval cycle 55 101 Procedure performance evaluation 124 Procedure request form, example 100 Procedure review 101 103 Procedure steps section 46 Procedure training 30 Procedure users 12 34 54 Procedure writing 33 see also Effective procedure writing branching 52 completeness and accuracy 35 62 conciseness 36 68 consistent presentation 36 determining which procedures to write 27 122 drafting a procedure 54 graphs 74 importance of 21 introductory sections 40 level of detail, appropriate 36 lists and tables 50 75 notes, cautions, warnings 51 65 procedure steps section 46 resources needed before beginning 33
150 Procedure writing (Continued) style, format, and terminology 36 49 tide 59 Procedures, see also Written procedures; Procedure writing alignments 75 batch process considerations 56 calculations 73 conditions or criteria 72 conditional instructions 72 considerations for effective 35 control 97 coordination with others 67 developing 5 22 98 107 development costs 108 as plant equipment 1 22 evaluation procedure, importance of 57 implementing a procedures project 23 list of types 27 maintenance, special considerations for 55 return on investment 112 temporary, identified 60 training 30 verifying critical steps 67 worldwide trend toward 3 Process flow diagrams 43 Process hazards analysis (PHA) xiii 43 81 123 Process safety management xiii 1 2 9 interrelationship with quality and environmental responsibilities 9
Processes, duplicate 62 Purpose section 41 151 Q Quality management 14 16 116 Quantitative terms 70 Quick reference cards in emergency operating procedures 90 R Readability 34 37 88 Reference section of procedures 43 Related actions, combining 69 Resources 33 identifying 26 Reviews and audits of procedures 17 55 Revisions and development, controlling 98 S Safety 5 16 18 28 and health considerations 18 systems, redundant/backup 81 Sample procedure formats 130 Signing off 67 68 sample formats showing 131 133 Special tools/equipment section 45 Specification sheets 43 Standards, government, industry, company 43 Step content 47 Step numbering 47 69
152 System descriptions 43 System design specifications 43 System upset xiv 79 T Tasks requiring written procedures 122 Title, procedure 59 Training, procedure 5 18 30 32 U Users, see Procedure users V Valve alignment 75 Voluntary guidelines 6 9 Vendor and supplier manuals 43 Visual indicators in EOPs 87 W World Bank 11 117 Manual of Industrial Hazard Assessment Techniques 4 117 Writing procedures, see Procedure writing Written procedures capitalization 49 64 caution box 42 45 48 52 65 132 134 determining tasks that require 122 development, reasons for 107 hard copy and electronic access 40 importance of 6 21
153 Written procedures (Continued) importance of format 37 line spacing 34 37 lists and tables 50 notes, cautions, warnings 51 page layout 37 precautions section 44 prerequisites section 45 72 purpose section 41 61 reference section 43 62 63 sequences within 70 special tools/equipment section 45 step content 47 step numbering 47 69 T-format 39 tide 59 writing style, format, terminology 49