Process Safety Management

R

Engineering and Management Skills to Prevent Accidents When operations include hazardous processes, the health and safety of your workers and the general public depends on ensuring that all your facilities’ assets are protected. EN Engineering’s team of PSM experts can help protect your personnel, the public, and your property from the potential dangers of operating hazardous industrial processes. When implemented properly, PSM systems can be effective in enhancing the safety of your operation, increasing productivity, and improving quality. EN Engineering’s expert consultants can work with you to create new, or enhance existing, PSM programs to improve your bottom line… and most importantly, save lives. Our PSM professionals consist of technical experts with vast industrial knowledge, operational experience, and a willingness to serve our clients’ needs. EN Engineering has worked

Key Markets Served Natural Gas Distribution Natural Gas Transmission Oil & Liquids Pipelines and Terminals Natural Gas Storage & LNG Midstream Oil & Gas Industrial Natural Gas Consumers Petroleum Refining Petrochemical & Process Chemical Electric Utility Food & Beverage Steel Making & Metals Processing

Pipeline Engineering

Integrity Services

a a a a a a a a

a a a a a a a a

with numerous major industrial clients to development and implement PSM programs. EN Engineering’s team of professionals can help you in evaluating and improving your existing PSM program to ensure safe operation and compliance with the Process Safety Management standards and regulations. If you have yet to develop a PSM program, EN Engineering can assist you in determining whether PSM requirements apply to your facility. We can then facilitate development and implementation of an entire program, or facets of a program, to ensure PSM compliancy. Contact EN Engineering to see how we can assist you to develop an operation that is more productive, more reliable, and safer.

Automation Electrical Services Engineering

a a a a a a a a a a a

a a a a a a a a a a a

Industrial Solutions

a a a a a

a

Process Safety Management

a a a a a a a a a a a

We Provide an Array of PSM Services • Process Safety Information • Process Hazard Analysis • Compliance Audits • Operating Procedures • Training • Mechanical Integrity • Incident Investigation • PSM Program Development

Process Safety Information

25+ Process Safety Management (PSM) Professionals on Staff 11th Fastest Growing Engineering Firms (Zweig Letter’s 2013 Hot Firm List) 151st Largest Engineering Design Firm (ENR Top 500 Rankings, 2013) 1994 EEC Begins Operations 8 Offices Across the United States

Operating Procedures

Contractors

Training

Pre Startup Safety Review

Mechanical Integrity

Hot Works Permits

100% Team Members with Roots in Refinery and Chemical Industry

2013 EEC Acquired by EN Engineering

Process Hazards Analysis Employee Participation

EN Engineering’s Process Safety Management By the Numbers

Protection of Employees

Incident Investigation

Management of Change

Emergency Planning & Response

Compliance Audits

Trade Secrets Documentation Control/Access Management Commitment

600+ Employees Company-wide 40+ States in which Our Team Members are Licensed Professional Engineers 240+ Degreed Engineers on Staff 21+ Languages in which our employees are fluent

What Our Clients Are Saying… “My projects get rave reviews from management. I credit EN Engineering for that success.” “EN Engineering is good at catching the things we forgot… They communicate very well.” “Every project has been done well. We have no regrets on any project.” “EN Engineering’s quality is good… better than the competition.” “We like them a lot… They have great talent that works in their culture”

Certified ISA84 SIL Verification Specialists The ISA84 (IEC61511) standard is important to you because it can help identify, reduce, and manage its process safety risks. The ANSI/ ISA-84.00.01 standard is recognized as sound engineering practice under OSHA’s process safety management standard’s performance based requirements.

“Always a pleasure to work with EN Engineering and quality is always consistent.”

Process Safety Information (PSI)

Process Hazards Analysis

The PSI provides key information related to the hazards of the HHCs used or produced in the process. As well, the PSI considers technology and equipment deployed in the process. The PSI enables the operators to identify, understand, and control the hazards posed by the processes involving HHCs.

Federal PSM Regulations require that all PSMcovered facilities shall perform an initial process hazard analysis (PHA) on processes covered by this standard. The PHA shall be appropriate to the complexity of the process and shall identify, evaluate, and control the hazards involved in the process.

Requirements:

• Update and revalidate at least Every FIVE (5) Years

Features:

Requirements:

• Update on continual basis to reflect changes to facility

Features:

• The information pertaining to process equipment design must be documented • Qualitative estimate of the consequences operating beyond the established process limits • Process Flow Diagrams (PFDs) that demonstrate normal and operational limitations of processes • Piping and Instrument Diagrams (P&IDs) that demonstrate updated PFD details and include crucial design criteria and operational limits of process components • Effective Management of Change (MOC) process ensures continual update of PSI

Benefits:

• Our broad PSM experience assists clients with the identification and correction of PSI deficiencies to ensure PSM compliance. • We utilize state-of-the-art database systems to facilitate development and maintenance of equipment databases for PSI. • We support an array of industry-leading CAD programs to facilitate update and development of PFDs and P&IDs.

• Layer of Protection Analysis (LOPA) • Advanced preparation for PHA noding P&IDs to facilitate detailed review of process • Incorporate information into PHA documentation software and lead client PHA team through process analysis • Reduce anticipated deficiencies with OSHA compliance and ensure PSM regulatory compliance • Prepare and deliver comprehensive PHA Report • A quantifiable approach to risk reduction can be achieved by using Layer of Protection Analysis (LOPA) methods

Benefits:

• Trained and experienced team leader will guide your PHA team through each hazard analysis. • Our team leaders are trained in PHA techniques including HAZOP and “What If” scenarios. They utilize proven scribing methods to ensure accurate documentation. • Operational experience and technical expertise ensure accurate review of process equipment, safety components, and safety instrumented systems.

Compliance Audits

Operating Procedures

Compliance Audits are intended to verify that the procedures, practices, and documentation required under the PSM standards are adequate and being followed at your facility as per OSHA 1910.119 (o).

PSM regulations require development and maintenance of written operating procedures that provide clear instructions for; tasks to be performed, data to be recorded, operating conditions to be maintained, samples to be collected, and safety and health precautions to be taken. Operating procedures should be reviewed by engineering staff and operating personnel to ensure accuracy. Operating pocedures should also provide practical instructions on how to safely perform job duties.

In-house audits are discouraged and often challenged by OSHA inspectors due to recognized potential for biases.

Requirements:

• Certify operating procedures are Current Every ONE (1) Year

Features:

Requirements: • Audit PSM program Every THREE (3) Years

Features: • Review site-specific PSM program for National Emphasis Program (NEP) regulatory and corporate guidelines compliance • Provide safety gap analysis to identify deficiencies in clients’ PSM program • Establish corrective action plan to improve overall PSM efforts

Benefits: • Our PSM professionals are trained in the auditing process before being assigned to an audit team. • We conduct mandated audits according to OSHA-published protocols, while maintaining consistency with our clients’ internal audit methodology. • In addition, EN Engineering can provide assistance to refinery clients with internal API 75 HF Alkylation audits.

• Operating Procedures must contain detailed, step-by-step instructions to ensure: all operators perform all tasks in the same manner; operators are told what is expected of them; and instructions are written to the level of understanding of the entry-level operator. • Operating Procedures should address: safe operation during all operating modes; operating limits; consequences of deviations; Safety and health considerations; and safety systems and functions.

Benefits: • Our operational and technical expertise ensures that we have a thorough understanding of processes and equipment while optimizing safe operating procedures. • EN Engineering can work onsite with your management, operators, and engineering personnel during the development phase and follow-up with a detailed recommendation process.

Mechanical Integrity

Training

PSM regulations require that a mechanical integrity (MI) program be in place to ensure that all equipment used to process, store, or handle highly hazardous chemicals is designed, constructed, installed, and maintained to minimize the risk of releases of such chemicals.

Good employee training is one of the most important steps to improve employee safety. Training helps employees understand what type of issues they may encounter while operating their process and what may cause these problems. Training can improve employee awareness of the process hazards involved in their jobs.

Requirements: • Inspections and Tests Periodically • Frequency of inspections and tests should be consistent with manufacturers’ recommendations, follow good engineering practices, and occur more often, if necessary based on prior operating experience.

Features: • ISA 84 (IEC61511) Safety Instrumented Systems Certified Experts • Develop & Implement Mechanical Integrity Programs & Procedures • QA/QC Program Implementation • Maintenance Personnel Training • Inspections and tests on process equipment • SIL Level Verification • Relief Valve Calculations

Benefits: • Our operational experience and technical expertise ensures that we have a thorough understanding of processes and equipment and can develop effective Mechanical Integrity programs. • We support an array of state-of-the-art software programs to analyze mechanical and process conditions to ensure safe operation of components.

Requirements: • Required for each employee involved in operating a process • Refresher training at least Every THREE (3) Years • Greater frequency “if necessary”

Features: • Initial training is required before an employee can be involved in operation of a newly assigned process and must cover: • Overview of the process • Overview of operating procedures • Specific safety and health hazards • Emergency operations including shutdown • Safe work practices

Benefits: • Our experienced personnel can develop and execute training programs specific to your facility and processes. • We offer on-site training at your facility to minimize disruption to your work force and allow in-person review of processes.

Incident Investigation PSM regulation requires that all incidents, including near misses, involving HHCs that could reasonably have resulted in a catastrophic release be investigated. The investigation should determine causal factors so that appropriate corrective actions can be developed and implemented to prevent similar events from occurring.

Requirements:

• Conduct as promptly as possible following an incident, but not Later Than 48 Hours Following an Incident

Features:

 n Incident Investigation team should be established A and consist of: • At least one person knowledgeable of the process being investigated • A contract employee if the incident involved work by the contractor • Other persons with appropriate knowledge and experience to thoroughly investigate and analyze the incident

Benefits: • We support an array of state-of-the-art software programs to analyze mechanical and process conditions to facilitate failure analyses. • EN Engineering PSM professionals are trained in the use of TapRoot® methodologies to streamline and organize the Incident Investigation process.

Complimentary Services With over 600 professionals company wide, the EN Engineering team includes experts in fields that complement the resources of our Industrial Solutions team. We also offer our clients expertise in Automation Services, Integrity Services, Pipeline Engineering, and Electrical Engineering, providing comprehensive solutions and seamless project execution.

Industrial Solutions Our Industrial Solutions Group provides a full spectrum of consulting and engineering services within a single team format concentrating on refineries, chemical facilities, and industrial processes. Our range of engineering disciplines includes but is not limited to the following: Electrical, Mechanical, Civil, Structural, Petroleum and Chemical Engineering. Our Industrial Solutions approach pairs strong project managers in tandem with an integrated team of appropriate engineering expertise to provide the most cohesive, efficient, and effective solutions that specifically meet your needs. First-hand operational experience and technical proficiency benefit the efforts of our PSM Group.

Platforms We Support Integrity Services Our Integrity Services Group provides an array of services to terminals & tank farms, refineries, chemical facilities, natural gas and hazardous liquids pipelines, gas utilities, water pipelines, and industrial customers. Today’s complex regulatory landscape has introduced an array of codes, standards, and operational requirements. Our Integrity Services professionals can help ensure that you operate the safest facilities and remain compliant with all applicable standards. Services include: Integrity Management, System Assessment & Risk Prioritization, Corrosion Control & Cathodic Protection, Integrity Field Services, Metallurgy & Applied Mechanics, and Operations Support.

Automation Services Our Automation Services Group provides automation integration expertise to refineries, process chemical plants, oil & gas pipelines, utilities, food & beverage processors, and power generators. EN Engineering’s Automation Group has been ranked as the 15th largest system integrator in the world, by Control Engineering magazine. We apply our expertise in systems automation to a wide range of industries where a focus on systems integrity and safety is critical. We provide experienced support utilizing the industry’s leading automation platforms. As one of the largest independent systems integrators in the United States we specify and implement best-in-class automation solutions based purely upon performance and “what’s best for the client.”

ANSYS Workbench

CFD & FE Engineering Simulation Software

Integraph® — CAESAR II® Pipe Stress Analysis

Codeware — COMPRESS™ ®

ASME VIII Pressure Vessel Design

Codeware® — INSPECT™ API 510 Mechanical Integrity for Pressure Vessels & Heat Exchangers

aspenOne® HYSIS®

Process Simulation

aspenOne® Aspen Exchanger Design & Ratiing (EDR)

Heat Exchanger Design & Rating

aspenOne® Aspen Economic Evaluation Capital Investment Project Evaluation

Ensoft LPILE Plus

Piling & Drilling Shaft Analysis

Bentley AutoPlant Piping 3D Process Piping Design

Bentley Microstation V8i

2D/3D CAD - Infrastructure Design

Bentley RAM

Steel & Concrete Structural Design/Analysis

Bentley STADD Pro

Steel & Concrete Structural Design/Analysis

Autodesk AutoCAD

Various CAD Drafting & Design

AutoCAD Civil 3D

3D Civil Site Design

SolidEdge ST with Femap 3D Modeling & FEA Analysis

Sokkia Robotic Total Station Advanced Survey Device

Autodesk Revit® Structure

Structural Design & BIM

RISA 3D

3D Structural Engineering Analysis & Design

This list represents some of the platforms we support and is not inclusive. As part of our corporate philosophy to provide the latest technology, we deploy new development resources on a regular basis. Please contact EN Engineering to verify most current support details if you do not see your desired platform.

FARO Focus 3D

3D Terrestrial Laser Scanning Device

Kubit Pointsense Plant 3D Laser Scan Point Cloud Piping Design

CAESAR II®

Covering a Wide Range of Industrial Applications EN Engineering focuses on providing effective solutions to meet challenging design requirements and solve clients’ problems. Our team of technical professionals has decades of operational and project experience in tandem with a wide variety of technical backgrounds. We have worked as owners & operators, doing what our clients do. This ensures we “hit the ground running” and provide practical help from day one! Over the years, EN Engineering has worked with customers representing a diverse range of industries and applications. As varied as these applications are, all of our solutions are engineered and delivered with a focus on exceeding expectations and building long term relationships with our customers.

Petroleum Refining EN Engineering staff has worked closely with petroleum refinery clients to prepare for PSM audit requirements set forth in the OSHA 2007 National Emphasis Program (NEP) for petroleum refineries. Our PSM professionals have vast technical knowledge and operational experience gained from previous employment with major petroleum refining companies. EN Engineering has worked with major refinery clients throughout the United States to develop, implement, and optimize their PSM programs and facilitate compliance with OSHA and EPA regulatory requirements.

Petrochemical & Chemical Processing Our PSM professionals have assisted petrochemical and chemical processing clients in compliance with OSHA Chemical National Emphasis Program (NEP). Our PSM experts have significant operational experience with chemical processing facilities and can provide immediate assistance with implementation and optimization of PSM programs. Our team is knowledgeable in the OSHA audit process and can help verify that the procedures, practices, and documentation required under the PSM standards are adequate and being followed at your facility.

Liquids Pipelines & Terminals EN Engineering has a wealth of experience in design and operation of liquids pipelines and storage terminals. We apply this expertise to truck & rail distribution facilities, storage terminals, and an array of petroleum & liquid pipeline infrastructure. Our PSM team can audit your facilities to assess the level of compliance with OSHA PSM regulation, 29 CFR 1910.119, and requirements of EPA RMP regulation, 40 CFR 68. We can address deficiencies found in your Process Safety Management program and provide recommendations to enhance operability and improve safety. From individual components to an all-encompassing PSM solution, our experts offer an array of tools to help ensure compliance with regulatory requirements.

Natural Gas EN Engineering has deep roots in the natural gas industry. With first-hand experience operating and maintaining gas infrastructure, our engineering professionals understand the challenges and objectives of the natural gas industry. We apply this expertise to natural gas transmission, distribution, processing, supplemental gas facilities, and storage infrastructure. Our team of PSM experts can help operators understand the benefits of a PSM program and can assist with implementation & optimization. If PSM regulatory requirements do not currently apply to your facility, implementation still makes a lot of sense. A Process Safety Management program can minimize accidents, protect people, and maximize profits. We encourage you to consider deployment of a PSM program in advance of any expansion of applicable regulations.

Summary of Applications Petroleum Refining • • • • • • • • • • • • • • • • •

Crude Oil Desalting Atmospheric & Vacuum Distillation Saturate Gas Fractionation Naphtha Hydrotreating Catalytic Reforming Isomerization Light Distillate Hydrotreating Heavy Distillate Hydrotreating Fluid Catalytic Cracking (FCC) FCC Gas Concentration C3-C4 Alkylation Polymerization Unit Hydrocracking Unit Solvent Deasphalting (SDA) Unit Lube Oil Solvent Refining & Dewaxing Units Utility Systems Sulfur Recovery

Petrochemical Production • • • •

BTX Fractionation Cumene Phenol BPA

Gasoline and LPG Treating • Caustic Treating • Amine Treating

Utility Systems • • • •

Boilers Cooling Towers Waste Water Treating Instrument Air

Storage Facilities • • • •

Crude Oil LPG Storage Vessels and Caverns Transportation Fuels Storage Tanks Truck and Railcar Loading

Natural Gas Industry • • • • • • • • • • •

Field Processing (Water, Sulfur, CO2, Condensate Removal) Collection and Distribution Networks Transmission Pipelines Compression Stations Pump Stations Natural Gas Liquids Fractionation Liquids Pipelines & Terminals Truck and Railcar Loading LNG Facilities Propane-Air Injection Plants C3 – C4 Vessel and Cavern Storage

Updated 2/2014

EN Engineering is a dedicated group of engineering professionals with decades of experience providing highest value innovative engineering solutions in the natural gas, liquids, power and processing industries that meet our clients’ needs, while consistently maintaining the highest level of ethics and integrity. Our success is achieved through the valued contributions of our talented and diverse employees. EN Engineering’s mission is to build and sustain long-term mutually beneficial client relationships and to grow as a leading engineering firm providing excellence from start to finish.

R

www.enengineering.com