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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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
