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

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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

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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