1. No category

XXX Plant (XX)
Guidelines
Information for Safety Report Development
XXX APPLICATION – XXX PLANT REQUIRED INFORMATION FOR FINAL SAFETY REPORT
FOREWORD
Following tables show the list of information and data which are required for the elaboration
of the Final Safety Report of XXX plant in XXX site.
The list is based on the requirements of law.
For each category, a detailed list of information is provided in following paragraph 1.
In order to be more comprehensive, the subsequent paragraph 2 presents the general Index
of Safety Report with identification of the elements to be provided for Final Safety Report
(FSR).
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XXX Plant (XX)
Guidelines
Information for Safety Report Development
1.
LIST OF REQUIRED INFORMATION
N.
Element
Note
1
General description of the
Check if description presented in XXX is updated and
unit.
complete with respect to the plant under
construction.
2
Lay out of the unit
The material is updated?
3
Quantified Process Flow
The material is updated?
Diagram
4
P&ID
For development of risk analysis. It is not planned to
attach to FSR.
It is required to elaborate a simplified P&ID (or
detailed Flow Sheet) for the sections of the plant in
which Top Event have been identified (reactor,
columns, quench), since the authority required more
details on each of the critical units.
5
Details on the hold up of
The material is updated?
dangerous substances
present in each
equipment.
6
Material Safety Data
MSDS of chemicals classified as dangerous substances
Sheets of the handled
(with specific risk phrases).
substances
7
Information regarding the
Details on how SMS will be implemented and
Safety Management
according to which standard.
System
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XXX Plant (XX)
Guidelines
Information for Safety Report Development
N.
Element
Note
8
General information on
Details on how connection will be made for power,
utilities connections.
fire water, cooling water, nitrogen, steam, etc.
Information on how the unit is protected against
sudden loss of utility.
9
10
Information on
Details on how eventual leakages from equipment
containment systems
might be collected to closed pits or dedicated basin.
Information on the
Notes on applicable standards (IEC, API, ASME, etc.)
applied standard for
for process equipment, electrical instruments, relief
design and construction
systems.
with evidence of
compliance to Italian and
European legislation
11
General information of
Notes on use of SIL Certified instruments, foreseen
standard for alarm/trip
test interval for the instruments of trip systems
system
12
13
General information on
Indication on the use of Certified DCS, PLC; if the DCS
control system
controls all the unit and all the variables.
Design of prevention to
Details on corrosion allowances for piping and
corrosion
equipment, expected corrosion rates for the selected
materials, inspection plans to monitor corrosion
14
Design of sewer network
Basis design of the different circuits with map of the
overall network
15
Design of fire fighting
Basis design for water curtains (flow rates, pressure),
network, including water
position of hydrants, monitors.
curtains, fire
A general lay out with details on different equipment
extinguishers.
to be provided.
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XXX Plant (XX)
Guidelines
Information for Safety Report Development
N.
Element
Note
16
Design of detection
Use of gas detection devices, use of video cameras,
network
indication of where the signals will be sent.
A general lay out with details on different equipment
to be provided.
17
Details on presence of
Use and storage of chemicals, with particular concern
additives and corrosive
to corrosive and / or flammable.
substances
18
General indications on
Indication of signals or physical barriers to prevent
routes for mechanical
potential interference between lines, vessels and
vehicles and criteria for
vehicles that will be moving inside the unit.
prevent mobile risks
A general lay out with details on main transport
routes to be provided.
19
General indications on
A general lay out with details on escape routing to be
Emergency planning
provided.
A copy (or at least the index) of Internal Emergency
Plan to be provided with details on connections with
XXX organization in managing emergencies
(emergency squad, responsibles, protective
equipment, etc.)
Connection with XXX in terms of emergency planning
is required.
20
Presence of emergency
Map with identification of portable fire extinguishers,
devices in the plant
foam units, first aid kits, emergency push buttons.
Could be same map or one map for each item.
21
List of safety procedure of
List of procedure associated to SMS which details the
the plan
safety principles inside the unit
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XXX Plant (XX)
Guidelines
Information for Safety Report Development
N.
Element
Note
22
Information on control
Indicate how the control room will be protected in
room
case of fire, toxic dispersion (internal ventilation, air
intakes, etc.)
23
Treatment units
Indications on the foreseen treatment units and
measure to prevent / reduce emissions, discharges,
etc.
Details on expected flow rates in production of
wastes, and general characterization of the wastes in
terms of dangerous properties.
24
25
General information of
Indicate the level of training that it is foreseen for the
training and technical
workers in terms of safe handling of dangerous
skills
substances.
General plant lay out in
Could be a common map with XXX plant.
the context of the
territory
26
Responsible for the design
References and experienced in such typology of
and construction of the
plants.
plant
Table n. 1 – Detailed information on general aspects of the plant
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XXX Plant (XX)
Guidelines
Information for Safety Report Development
2.
INDEX OF SAFETY REPORT
The following scheme associates a specific colour to each paragraph (for the general index)
and to each Attachment (index of attachments).
At the end of each list a dedicated legend is provided.
Index of technical relation
FOREWORD
7
1.A.1
IDENTIFICATION AND POSITION OF THE PLANT
11
1.A.1.1
GENERAL INFORMATION
11
1.A.1.1.1 Name and address of the operator
11
1.A.1.1.2 Identification and position of the plant – Responsible
11
1.A.1.1.3 Responsible for design and construction of the plant
12
1.A.1.1.4 Responsible for development of Safety Report
12
1.A.1.2
13
geographical position of the plant
1.A.1.2.1 Chorography of the area
13
1.A.1.2.2 Position of the establishment
14
1.A.1.2.3 Lay out of processing units
16
1.A.1.2.4 Description of the environment
16
1.A.2
SAFETY MANAGEMENT SYSTEM
18
1.A.2.1
General
18
1.A.2.2
Policy for health, safety and Environmental protection
18
1.A.2.3
Guidelines of the System
19
1.A.2.4
Structure
20
1.A.2.5
Implementation of Guidelines and responsibilities
20
1.A.2.6
Risk assessment
20
1.A.2.6.1 Prevention measures
20
1.A.2.6.2 Emergency management
21
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Guidelines
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1.B.1
INFORMATION OF THE PLANT
22
1.B.1.1
ORGANIZATION
22
1.B.1.1.1 Organization chart
22
1.B.1.1.2 Personnel
23
1.B.1.1.3 Minimum requirements for training
25
1.B.1.2
28
DESCRIPTION OF THE ACTIVITY
1.B.1.2.1 General description of the activity
28
1.B.1.2.2 Classification of activity according to Annex IV to O.M. 21 Feb 1985 of Ministry of
Health
33
1.B.1.2.3 Plant typology and technology
34
1.B.1.2.4 Block schemes and Process Flow Diagrams
50
1.B.1.2.5 Processing Capacity of the units
50
1.B.1.2.6 Dangerous substances
51
1.B.1.3
PRELIMINARY ANALYSIS FOR CRITICAL UNITS IDENTIFICATION
54
1.C.1
SAFETY OF THE PLANT
63
1.C.1.1
HEALTH AND SAFETY ASPECTS
63
1.C.1.1.1 Problems associated to health and safety aspects
63
1.C.1.1.2 Historical analysis
63
1.C.1.2
POSSIBILITY FOR RUN AWAY REACTIONS
65
1.C.1.3
METEOROLOGICAL DATA
66
1.C.1.3.1 Meteorological data of the area
66
1.C.1.3.2 Historical analysis on storms, earthquakes
67
1.C.1.4
POSSIBLE INTERACTION WITH OTHER PLANTS
68
1.C.1.5
ANALYSIS OF ACCIDENTS
68
1.C.1.5.1 Identification of Top Events
68
1.C.1.5.2 Position of critical points
70
1.C.1.5.3 Behaviour in case of unavailability of utilities
70
1.C.1.6
75
ESTIMATE OF CONSEQUENCE OF SCENARIOS
1.C.1.6.1 Glossary
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1.C.1.6.2 Top Events synthesis Table
76
1.C.1.7
83
SAFETY MEASURES TO PREVENT ACCIDENTS
1.C.1.7.1 Technical measures
83
1.C.1.7.2 Measure to prevent human error
89
1.C.1.7.3 Precautions against natural events
91
1.C.1.7.4 Behaviour of the plant in start up, shut down, particular assets
92
1.C.1.8
92
PRECAUTIONS ADOPTED AT DESIGN LEVEL
1.C.1.8.1 Technical standards and criteria adopted for electrical units, control system,
protection against atmospheric charges
1.C.1.8.2 Technical standards and criteria adopted for the design of Relief Systems for
pressure vessels, equipment and piping
1.C.1.8.3 Functional vents to atmosphere of dangerous vapours
94
1.C.1.8.4 Control of Pressure Safety Valves and Trip Systems
96
1.C.1.8.5 Technical standards and criteria adopted for the design of vessel, equipment and
piping
96
1.C.1.8.6 Protection of dangerous substances vessels against corrosion
96
1.C.1.8.7 Corrosive substances
97
1.C.1.8.8 Criteria for definition of corrosion allowances
98
1.C.1.8.9 Specific procedures for control of fabrication and installation of process equipment
98
1.C.1.8.10 Safety trip systems and test interval of the components
98
1.C.1.8.11 Safety measure against formation of flammable mixtures in closed areas
100
1.C.1.8.12 Ventilation of the closed areas
100
1.C.1.8.13 Safety Measures against mobile vehicles
101
1.C.1.9
DETECTION SYSTEMS
103
1.D.1
EMERGENCY SITUATIONS AND RELEVANT MEASURES
105
1.D.1.1
RELEASED SUBSTANCES IN CASE OF EMERGENCY
105
1.D.1.2
POTENTIAL EFFECTS IN CASE OF FIRE / EXPLOSION
105
1.D.1.3
MITIGATING MEASURES
106
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1.D.1.3.1 Measures to contain accidental release of flammable/toxic substances
106
1.D.1.4
OPERATING MANUAL
109
1.D.1.5
EMERGENCY SIGNALS
109
1.D.1.5.1 Adopted systems for identification of potential source of accidental events 109
1.D.1.6
SOURCES OF MOBILE RISKS
110
1.D.1.7
MEASURES TO PREVENT CATASTROPHIC RUPTURES
110
1.D.1.8
MEASURES FOR EVACUATION
110
1.D.1.9
ACCESS RESTRICTION TO PROCESSING UNITS
110
1.D.1.10 FIRE FIGHTING MEASURES
113
1.D.1.10.1Equipment, fixed plants and organization against fire
113
1.D.1.10.2 Water draining network
117
1.D.1.10.3 Availability of fire water
117
1.D.1.10.4 Fire prevention Certificate
118
1.D.1.10.5 Fire extinguishing with inert gas and/or steam
118
1.D.1.11
119
EMERGENCY SITUATIONS AND PLANS
1.D.1.11.1 Position of control room, laboratiers, etc.
119
1.D.1.11.2 Internal and External Communication devices
119
1.D.1.11.3 Lay out with indication of position of Emergency devices
120
1.D.1.11.4 Training on Internal Emergency Planning
120
1.D.1.11.5 Escape Ways
121
1.D.1.11.6 Internal Emergency Plan
121
1.D.1.11.7 Responsibles for activation of emergency plan
122
1.E.1.
TRATMENT PLANTS FOR VAPOURS, LIQUIDS AND SOLIDS
123
1.E.1.1.
LIQUID DISCHARGES TREATMENT UNITS
123
1.E.1.1.1. Description of treatment units
123
1.E.1.1.2
Sewer network
123
1.E.1.2
STORAGE OF REFLUES
124
1.E.1.3
ABATEMENT OF GASOUES EMISSIONS
125
1.F.1.
INSURANCE AGAINST RISKS OF MAJOR ACCIDENTS
126
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XXX Plant (XX)
Guidelines
Information for Safety Report Development
Index of attachment
Following are main attachment provided by XXX in the Safety Report for XXX plant.
ATTACHMENT A1: Reference of ICARO srl
ATTACHMENT A2: Maps of the territory surrounding the establishment
ATTACHMENT A3: General Lay out of Merano plant
ATTACHMENT A4: Lay out of Merano plant with identification of mobile vehicle routes
ATTACHMENT A5: Lay out of Merano plant with identification of dangerous substances
ATTACHMENT A6: Policy on prevention of major accidents
ATTACHMENT A7: Manual of the Health, Safety end Environmental Management System
ATTACHMENT A8: Copy of Environmental Certification acquired by the plant
ATTACHMENT B1: Organization chart of the plant
ATTACHMENT B2: Training courses for personnel for past year
ATTACHMENT B3: Material Safety Data Sheets for dangerous substances
ATTACHMENT B4: Extract from Environmental Declaration of the plant
ATTACHMENT B5: Block diagrams for the activity
ATTACHMENT B6: Process flow diagrams for storage section
ATTACHMENT B7: Process flow diagrams for distillation section
ATTACHMENT B8: Process flow diagrams for utilities distribution
ATTACHMENT B9: Index Method summary tables
ATTACHMENT C1: Historical analysis statistics
ATTACHMENT C2: Meteorological data of the area
ATTACHMENT C3: Sewer network lay out
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XXX Plant (XX)
Guidelines
Information for Safety Report Development
ATTACHMENT C4: Description of the adopted trip systems
ATTACHMENT C5: Gas/fire detection systems lay ouy
ATTACHMENT C6: Procedure for testing of gas/fire detection systems
ATTACHMENT C7: Description of main elements for gas/fire detection
ATTACHMENT C8: Safety measure against flooding from the Sinigo River
ATTACHMENT C9: Safety measure for the rail tankers of chlorosilanes
ATTACHMENT C10: Details flow schemes of the sections of plant in which Top Event have
been identified
ATTACHMENT D1: List of safety procedures of the plant
ATTACHMENT D2: Fire fighting network of the plant
ATTACHMENT D3: Description of water curtains of the plant
ATTACHMENT D4: Lay out with identification of first aid kits in the plant
ATTACHMENT D5: Lay out with indication of fixed fire extinguishing devices
ATTACHMENT D6: Portable fire extinguishers lay out
ATTACHMENT D7: Personal Protection Devices lay out
ATTACHMENT D8: Emergency push button lay out
ATTACHMENT D9: Escape routes lay out
ATTACHMENT D10: Copy of Internal Emergency Plan
ATTACHMENT D11: Technical data sheets for foam and adsorbent devices
ATTACHMENT D12: Fire water containment devices
ATTACHMENT D13: Description of main buildings inside the plant
ANNEX 1: DETAILED RISK ASSESSMENT
ANNEX 2: TERRITORIAL COMPATIBILITY OF THE SITE
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