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The document discusses management of change (MOC) policies and procedures. It explains that plants undergo various changes that could introduce new hazards, so changes should be analyzed to identify risks. Each plant has an MOC process to manage changes safely and provide benefits like fewer accidents. The MOC process involves identifying problems, evaluating proposed modifications, approving changes, updating documentation, notifying staff, implementing changes, and monitoring impacts. The MOC procedure should be used for critical, emergency, temporary, or instrumentation changes. Checklists are provided to evaluate modified changes and ensure pre-start up safety reviews are conducted when restarting production after changes.
The document discusses management of change (MOC) policies and procedures. It explains that plants undergo various changes that could introduce new hazards, so changes should be analyzed to identify risks. Each plant has an MOC process to manage changes safely and provide benefits like fewer accidents. The MOC process involves identifying problems, evaluating proposed modifications, approving changes, updating documentation, notifying staff, implementing changes, and monitoring impacts. The MOC procedure should be used for critical, emergency, temporary, or instrumentation changes. Checklists are provided to evaluate modified changes and ensure pre-start up safety reviews are conducted when restarting production after changes.
The document discusses management of change (MOC) policies and procedures. It explains that plants undergo various changes that could introduce new hazards, so changes should be analyzed to identify risks. Each plant has an MOC process to manage changes safely and provide benefits like fewer accidents. The MOC process involves identifying problems, evaluating proposed modifications, approving changes, updating documentation, notifying staff, implementing changes, and monitoring impacts. The MOC procedure should be used for critical, emergency, temporary, or instrumentation changes. Checklists are provided to evaluate modified changes and ensure pre-start up safety reviews are conducted when restarting production after changes.
Each plant is subject to changes involving machinery, equipment, instrumentation,
processes to increase productivity or correct hazardous situations. In some cases there are temporary modifications such as connections, by-pass, sometimes there are also organizational changes (staff reduction, elimination of positions, mergers). All these changes have the potential to create new workplace hazards, some of which are not immediately recognizable. Although some changes are more critical than others, any change should be analyzed in order to identify the risks and dangers inherent in it. To this end, each plant has a policy and a change management procedure (MOC), which can provide the following benefits: 1. Less releases of dangerous substances 2. Less risky maintenance 3. Production due to minor business interruption tends to increase 4. Few accidents lead to fewer economic losses due to less frequent stops 5. Increases the reputation of the company towards customers, stakeholders, employees, residents, government agencies, insurance companies, banks. The process of managing the changes is: Identification of the problem (it is essential that all staff is involved in the change management process, a lack of education and experience does not mean that the person cannot come up with useful suggestions) Evaluation of the proposed modification Basic Cause Analysis (Detailed analysis is required to identify the root causes of the problem and areas where editing can be most effective) Obtaining approval for modification (prior to modification, executives / managers must formally approve it) updating documentation (prior to implementation, all security documentation needs updating, which means: staff training involved in modification, updating of operating procedures, updating project designs, implementing corrective actions after HAZOP) Notify everyone involved (before the implementation, all staff involved will be updated) Implementation of the modification (the modification is implemented as planned) monitoring the change (an impact analysis of the change in operations needs to be done). When should the edit procedure be used?: Edit types: In Kind If the change corresponds to replacing a piece with another that specifies or functions then in this case the Moc procedure is not required. Critical change A critical change can lead to an accident and therefore be handled with Moc. Small / large change Care must be taken to small changes that can lead to serious accident if neglected. Emergency change Every change of emergency should be revised with Moc to make sure there are no unanticipated problems and make sure that the modification is documented and monitored. Temporary change Usually they are done to keep the drive running while a piece of equipment is replaced. A temporary change should always have a forward date. These changes must be submitted to MOC. Instrumentation change Usually a modification of instrumentation systems requires MOC. CHECKING LIST FOR MODIFIED MANAGEMENT 1. Is the amendment envisaging the use of different chemicals that may react with others already present in the process? 2. Can the amendment include the production of by-products or other reactions or the introduction of impurities with new substances? 3. Do you develop more warmth of reaction? 4. Is the modification for some appliances to work outside the approved process limits for them? 5. Does the proposed amendment consider chemical compatibility with equipment materials? 6. Are there any impacts on employee health? 7. Has the process for the change been subjected to a proper safety analysis by a qualified person? 8. Is there a new equipment inspection to verify that they are in accordance with specifications? 9. Have the drawings and procedures been updated to take account of the changes? 10. Have the right channels of communication been established for people affected by the changes? 11. Have the verification of the modalities of the instrumentation been carried out? Before authorizing a plant startup, the manager must conduct a pre-start up safety review. While Osha Americana expects such an analysis for new plants or modified before production starts. Typically, analysis Is led by a team of people in production, maintenance, research and development and security. An example checklist is provided: PRE-START UP SAFETY REVIEW (PSSR) CHECKLIST 1. Have all the recommendations made in Haze been implemented? 2. Has a list of all critical safety equipment been prepared? 3. Are all critical security devices installed and running? 4. Has the operating manual been compiled and approved? 5. Have production procedures (SOPs) been documented including startup and shutdown procedures? 6. Are production and maintenance personnel appropriately trained in operational and safety procedures? 7. Does the procedure for managing the changes apply? 8. Have all instrumentation loops and DCS/ PLC systems been tested? 9. Is there a structure for people with emergency services? 10. Has the internal emergency plan been made and applied? Bibliographic references: 1) guidelines for safe operation and maintenance CCPS AIChE