API RP 754-2016 Process Safety Performance Indicators for the Refining and Petrochemical Industries (SECOND EDITION ERTA JUNE 2017) .pdf

1、Process Safety Performance Indicators for the Refining and Petrochemical IndustriesAPI RECOMMENDED PRACTICE 754 SECOND EDITION, APRIL 2016Special NotesAPI publications necessarily address problems of a general nature. With respect to particular circumstances, local, state, and federal laws and regul

2、ations should be reviewed.Neither API nor any of APIs employees, subcontractors, consultants, committees, or other assignees make any warranty or representation, either express or implied, with respect to the accuracy, completeness, or usefulness of the information contained herein, or assume any li

3、ability or responsibility for any use, or the results of such use, of any information or process disclosed in this publication. Neither API nor any of APIs employees, subcontractors, consultants, or other assignees represent that use of this publication would not infringe upon privately owned rights

4、.API publications may be used by anyone desiring to do so. Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly

5、 disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any authorities having jurisdiction with which this publication may conflict.API publications are published to facilitate the broad availability of proven, sound engineering and operating pra

6、ctices. These publications are not intended to obviate the need for applying sound engineering judgment regarding when and where these publications should be utilized. The formulation and publication of API publications is not intended in any way to inhibit anyone from using any other practices.Any

7、manufacturer marking equipment or materials in conformance with the marking requirements of an API standard is solely responsible for complying with all the applicable requirements of that standard. API does not represent, warrant, or guarantee that such products do in fact conform to the applicable

8、 API standard.All rights reserved. No part of this work may be reproduced, translated, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher. Contact the Publisher, API Publishing

9、Services, 1220 L Street, NW, Washington, DC 20005.Copyright 2016 American Petroleum InstituteForewordNothing contained in any API publication is to be construed as granting any right, by implication or otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by lette

10、rs patent. Neither should anything contained in the publication be construed as insuring anyone against liability for infringement of letters patent.Within the API naming convention, standards may be designated as “specifications”, “recommended practices”, or “standards”. A “specification” is a docu

11、ment written to facilitate communications between purchasers, manufacturers, and/or service suppliers. Specifications may include datasheets that may be used in industrial transactions. A “recommended practice” is a document that communicates recognized industry practices. Recommended practices may

12、include both mandatory and non-mandatory requirements. A “standard” is a document that combines elements of both specifications and recommended practices.Shall: As used in a recommended practice, “shall” denotes a minimum requirement in order to conform to the Recommended Practice (RP).Should: As us

13、ed in a recommended practice, “should” denotes a recommendation or that which is advised but not required in order to conform to the RP.This document was produced under API standardization procedures that ensure appropriate notification and participation in the developmental process and is designate

14、d as an API standard. Questions concerning the interpretation of the content of this publication or comments and questions concerning the procedures under which this publication was developed should be directed in writing to the Director of Standards, American Petroleum Institute, 1220 L Street, NW,

15、 Washington, DC 20005. Requests for permission to reproduce or translate all or any part of the material published herein should also be addressed to the director.Generally, API standards are reviewed and revised, reaffirmed, or withdrawn at least every five years. A one-time extension of up to two

16、years may be added to this review cycle. Status of the publication can be ascertained from the API Standards Department, telephone (202) 682-8000. A catalog of API publications and materials is published annually by API, 1220 L Street, NW, Washington, DC 20005.Suggested revisions are invited and sho

17、uld be submitted to the Standards Department, API, 1220 L Street, NW, Washington, DC 20005, standardsapi.org.iiiContentsPage1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.1

18、 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.2 Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19、. . . . . . . . . . . . . . . . . . 11.3 Guiding Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Normative References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Terms, Definitions, Acronyms, and Abbreviations . . . . . . . . . . .

21、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.1 Terms and Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.2 Acronyms and Abbreviations. . . . . . . . . . . . . . . . . . . .

22、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Leading and Lagging Performance Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Tier 1 Performance IndicatorProcess Safety Event (T-1 PSE) . . . . . . . .

23、 . . . . . . . . . . . . . . . . . . . . . . . . . 125.1 Tier 1 Indicator Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125.2 Tier 1 Indicator Definition and Consequences. . . . . . . . . . . . . . . . . . . .

24、. . . . . . . . . . . . . . . . . . . . . . . . . . 125.3 Calculation of Tier 1 PSE Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145.4 Optional Tier 1 PSE Severity Weighting . . . . . . . . . . . . . . . . . . . . . . . .

25、. . . . . . . . . . . . . . . . . . . . . . . . . . . 146 Tier 2 Performance IndicatorProcess Safety Events (T-2 PSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146.1 Tier 2 Indicator Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

26、 . . . . . . . . . . . . . . . . . . . . 146.2 Tier 2 Indicator Definition and Consequences. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146.3 Calculation of Tier 2 PSE Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27、. . . . . . . . . . . . . . . . . . . 187 Tier 3 Performance IndicatorsChallenges to Safety Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187.1 Purpose of Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28、 . . . . . . . . . . . . . 187.2 Examples of Tier 3 PSEs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198 Tier 4 Performance IndicatorsOperating Discipline and Management System Performance . . . . . . . 228.1 General

29、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228.2 Purpose of Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30、 . . . . . . . . 228.3 Examples of Tier 4 Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 Guidelines for Selection of Process Safety Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31、. . . . . . 239.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239.2 Purpose of Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32、. . . . . . . . . . . . . . . . . . . . . 239.3 Lagging versus Leading Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249.4 Characteristics of Effective Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

33、 . . . . . . . . . . . . . . . . . . . . 249.5 Selection of Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2410 Reporting Performance Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34、 . . . . . . . . . . . . . . . . . . . . . . . . . . 2510.1 Format and Forum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2510.2 Transparency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2510.3 Stakeholder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2510.4 PSE Data Capture . . . . . . . . . . . . . .

36、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Annex A (informative) Application to Petroleum Pipeline and Terminal Operations . . . . . . . . . . . . . . . . . . . . 37Annex B (informative) Application to Retail Service Stations . . .

37、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Annex C (informative) Oil and Gas Drilling and Production Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Annex D (informative) Tier 1 PSE Severity Weighting . . . . . . . . . . . . . . . . . . . . .

38、. . . . . . . . . . . . . . . . . . . . . . . . 41Annex E (informative) PSE Examples and Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Annex F (informative) Listing of Chemicals Sorted by Threshold Quantity (Based on UN Dangerous Goods Hazard C

39、lass or Grouping) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Annex G (informative) Application of Threshold Release Categories to Multicomponent Releases . . . . . . . 71Annex H (informative) PSE Tier 1/Tier 2 Deter

40、mination Decision Logic Tree . . . . . . . . . . . . . . . . . . . . . . . . . . 74Annex I (informative) Guidance for Implementation of Tier 3 and Tier 4 Indicators . . . . . . . . . . . . . . . . . . . . . 75Annex J (informative) Tier 4 Example Indicators . . . . . . . . . . . . . . . . . . . . . .

41、 . . . . . . . . . . . . . . . . . . . . . . . . . . . 95Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107vPageFigures1 “Swiss Cheese (Static) Model” and “Spinning Disk (Dynam

42、ic) Model” . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Process Safety Indicator Pyramid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Example of Safe Operating Limit for Tank Level . . . . . . . . . . . . . . . . .

43、. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19D.1 Tier 1 PSE Severity Weighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44D.2 Tier 1 PSE Trend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44F.1 Inhalation Toxicity: Packing Group and Hazard Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70G.1 Flammability Limits of Methane, Nitrogen, Oxygen Mixtures . . . . . . . . . .

45、 . . . . . . . . . . . . . . . . . . . . . . . . . 72H.1 PSE Tier 1/Tier 2 Determination Decision Logic Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74I.1 Personal Safety/Process Safety Graphic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

46、. . . . . . . . . . . . . . . . . . . . 77I.2 Illustration of Process Safety Elements Relating to Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78I.3 Daily Indicator Listing Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

47、. . . . . . . . . . . . . . . 79I.4 Illustration of Data Flow and Need for Categorization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84I.5 Example of Data Funneling Flow Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

48、 . . . . . . . . 87I.6 Example PSE Tier 3 Other LOPC Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88I.7 Example PSE Tier 3 Other LOPC Graph by Plant and Process Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89I.8 Examp

49、le PSE Tier 3 Other LOPC Graph for Plant 1 FCC and Alkylation Units by Equipment Involved 90I.9 Example PSE Tier 3 Other LOPC Graph by Plant and Equipment Involved . . . . . . . . . . . . . . . . . . . . . . . 90I.10 Example PSE Tier 3 Other LOPC Graph by Plant and Management System Root Causes . . . . . . . . . . . 91I.11 Example PSE Tier 3 Other LOPC Graph by Plant and Mode of Operation . . . . . . . . . . . . . . . . . . . . . . . . 91I.12 Example of Moving Average for Demands on Safety Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92I.13 Example of Mo