 |
Writing Operating Procedures For Process Plants |
| Ian S. Sutton
302 pages. Paperback 2nd Edition, 1995 ISBN 1-57502-057-2 Price: $35.00 (U.S.) |
|
Writing Operating Procedures For Process Plants |
| Ian S. Sutton
302 pages. Paperback 2nd Edition, 1995 ISBN 1-57502-057-2 Price: $35.00 (U.S.) |
Summary
If you are writing Operating Procedures or developing a process safety program, this practical, sensible book - which is based on years of experience in a wide variety of industries - will provide you with useful guidance.
Writing Operating Procedures For Process Plants helps you organize a procedures-writing project so as to produce a high quality manual - one that the operators will want to use - as efficiently and as quickly as possible. The book also describes how to write procedures so as to meet process safety management requirements. The book emphasizes practical issues such as:
Contents
Chapter 1
The Operating Manual
Introduction Organization Of This Book Definition Of Operating Procedures Design Or Operating Intent Written Instructions Operations Operating Manuals/Operating Procedures Ownership Accountability Signs Of Problems Justification And Objectives For A Procedures-Writing Project Safety Economics Improved Operational Techniques Regulations And Standards Training Technical Human Error Slips Mistakes Violations Twelve Guidelines The Users Experienced Operators Familiar With The Unit Experienced Operators Unfamiliar With The Unit Inexperienced Operators Technical Staff / Management Translators Auditors / Inspectors Different Industries Batch Plants The Process Industries Food Processing The Nuclear Power Industry Multiple Goals Five Volume Structure Volume I - Operating Instructions Volume II - Operating Information Volume III - Emergency Operating And Shutdown Procedures Volume IV - Troubleshooting Manual Volume V - Initial Start-Up Manual Maintenance Of The Procedures Comparison With Software Data Base Comparison Large Amount Of Information / Indexing Randomness Similar Structure Modular Structure Desk-Top Publishing Software Top-Down Programming / Writing Expert Systems Project Management Auditing The Procedures External Audits Internal AuditsChapter 2
Introduction Modular Design Modular Structure Module Linkage Top-Down Development Module Design The Title Block The Operating Instructions The Authorization Block Complete Module Limitations Of Modularity Graphics Photographs P & ID's Iconic Flow Diagrams Maps / Plot Plans Layout - Two-Page Modules Facing Pages Four-Page Setup Integration Of Text And Graphics Alternative Layouts Layout - Continuous Text Start-Up Procedures The Starting Point Start-Up Timeline Shutdown Procedures Levels Of Shutdown Shutdown Hazards Normal Operations Routine Rounds Routine Tasks Maintenance Turnover Procedures Permit To Work Procedures Writing Permit To Work Procedures Design Of The Work Permit Temporary Operations Generic Procedures And Vendor Manuals Generic Procedures Vendor Manuals Level Of Detail Sources Of Information For Volume I Interviewing The Operator Existing Procedures Logsheets, Laboratory Data And DCS Records Log Books Batch OperationsChapter 3
Introduction Operator Duties And Responsibilities Process Description Process Overview Process Block Diagram Process Control Strategy Process Flow Diagram (PFD) Piping And Instrument Diagram (P&ID) Isometrics Models Other Process Information Safety And Health Information Special Or Unique Hazards Inadvertent Mixing Safety Systems And Their Functions Material Safety Data Sheets (MSDS) Safety Equipment And Clothing Operating Limits Title Block Information Block Equipment And Valve Information Equipment Valves Format Of Volume IIChapter 4
Introduction Emergency Situations Types Of Accident Event-Defined Accidents Result-Defined Accidents The Emergency Operations And Shutdown Manual - Volume III Emergency Operations Emergency Shutdown Format Of Volume III Emergency Response Manual (ERM) Other OSHA Emergency Response Regulations Troubleshooting - Volume IV The Nature Of Troubleshooting Troubleshooting Using The HAZOP Technique The Use Of Expert Systems For Troubleshooting Worst Case ScenarioChapter 5
Introduction Development Of Volume V The Licensor The Engineering Contractor Equipment Vendors The Operating Company The Start-Up Plan Phase 1 - Mechanical Completion Phase 2 - Precommissioning 1. Prepare Turnover Packages 2. Develop A Blind List 3. Develop A Punch List 4. Check Equipment 5. Check Piping Systems 6. Check Instruments / Instrument Loops 7. Check Safety Systems 8. Hydrotest Phase 3 - Commissioning 1. System Flushing 2. Commissioning / Checking Of Utilities 3. Pressure / Leak Testing 4. Nitrogen Purge 5. Refractory Dryout 6. Chemical Cleaning 7. Catalyst Loading / Activation Phases 4 and 5 - Start-Up And Line-Out The Start-Up Team The Operating Company The Engineering Company Licensor(s) / Equipment VendorsChapter 6
Introduction The Reader Method Of Reading Reading Grade Level Languages Other Than English Writing The Procedures Minimalist Writing Writing Styles Editing Prototyping Plan To Throw One Away Writing Guidelines Publishing The Procedures Layout/Format Indexing Glossary The Use Of Color The Binder Location Of The Procedures Laminated Cards Hip-Pocket Guides On-Line Documentation Computer Hardware Computers Printers Scanners And Digital Cameras Software Publishing Software Project Management Software Graphics And CADChapter 7
Introduction The Writer's Guide The Project Manual Project Teams Project Manager The Resource Team The Publishing Team Project Management Goals The Mythical Man-Month Tracking System Filing And Disk Management Development Of Volume I - The Operating Procedures The Cost Of Writing ProceduresChapter 8
Introduction Federal Regulations Fundamentals Of PSM Management Performance Based / Non-Prescriptive Thinking Process Compliance Integration Of The Elements Of PSM PSM Management Elements Of PSM As Defined By 29 CFR 1910.119 Employee Participation Process Safety Information Process Hazards Analysis (PHA) Types Of PHA HAZOP's And Procedures Operating Procedures Training Basic / Generic Training Plant Training Initial Start-Up Training On The Job Training Computer-Based Training Testing Certification Contractors Pre-Startup Safety Review Mechanical Integrity Hot Work Management Of Change Control Of Change Management Of Change And Operating Procedures Use Of Blank Process Flow Diagrams Replacement In Kind Incident Investigation Emergency Planning And Response Compliance Audits Compliance Guides Examples Of Detailed Audit Forms Trade Secrets Other Regulations And Standards The EPA Risk Management Program (RMP) States Industry Standards