Chemical Processing-August 2008

LifecycLe Step Hazard anaLySiS exampLe metric total number of hazard and risk analysis scheduled during defined interval • Number completed • Number behind schedule • Percentage hazard and risk analysis behind schedule • For those behind schedule, total number of days behind schedule deSign BaSiS Total number of safety equipment • Number of equipment with as-built documentation • Number of equipment with redlined or missing documentation • Percentage of equipment with redlined or missing documentation mecHanicaL integrity Total number of inspections scheduled during defined interval • Number of inspections on schedule but incomplete • Number of inspections completed • Number of inspection behind schedule • Percent on time for inspection • Percent behind schedule for inspection • For completed, number of successful inspections • Percentage of successful inspections Total number of equipment tests scheduled during defined interval • Number of tests incomplete • Number of tests completed • Number of test behind schedule • Percent on schedule for test • Percent behind schedule for test For completed tests: • Number of tests with “as found” within equipment specification • Number of tests with “as found” outside equipment specification (i.e., failed dangerously, failed safe or degraded state) • Percentage of tests within equipment specification • Percentage of tests outside equipment specification Total number of safety equipment • Total number of failures found by diagnostics • Total number of failures found by inspection and testing • Total number of failures requiring equipment repair or replacement • Total number of failed equipment returned to service within allowable repair time • Percentage of equipment returned to service within allowable repair time degraded OperatiOn Total number of safety equipment that are out of service (bypassed, disabled, overridden or under test/repair) during process operation for defined interval • Total number hours that safety equipment is out of service • Number of safety equipment that are returned to service within allowable repair time • Number of safety equipment that are out of service, but covered under MOC prOceSS perfOrmance Percentage of start-ups involving abnormal or emergency operation Total number of process shutdowns during defined interval • Number due to spurious operation of safety equipment • Number due to abnormal or emergency operation total number of safety alarms during defined interval • Number of standing or nuisance alarms • Number of safety alarms requiring response Table 1. Each lifecycle step for an instrumented safety system should have metrics. August 2008 chemicAlprocessing.com 34 http://chemicalprocessing.com

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Chemical Processing- August 2008 Contents From the Editor ChemicalProcessing.com Field Notes In Process Energy Saver Compliance Advisor Protect your Plant What’s on Tap for Water? Keep Operations Safe Polystyrene Plant Gains Extra Output and More Process Puzzler Plant InSites Equipment & Services Adlits Product Spotlight/Classifieds Ad Index End Point

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