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In the course of our consulting activities, Kenexis often learns of industry trends and regulatory
initiatives that impact the way that operating companies do their business in terms of process safety and engineered
safeguards. In order to ensure that our clients are kept up to date with the most recent industry trends we periodically
issue company advisories to communicate the latest information.
CA - 07 - Ice Storm Solenoid Latch Failure
Severe weather can impact the performance of controls in general and safety instrumented systems specifically.
In areas where severe weather is not common, the effect can be quite dangerous. This advisory presents an example of
where an ice storm in the mid-west resulted in dangerous failures (common cause) of all valves with solenoids with manual
reset latches.
CA - 07 - Ice Storm Latch Failure (PDF - 23k)
CA - 06 - Instrument Air Pressure Safety Issues
Instrument air systems are an important but often overlooked component in a safety instrumented system.
The lack of attention is primarily caused by the inherently safer design of most systems which go to the safe state upon
loss of instrument air pressure. While not extremely common, instrument air systems can cause dangerous failures of
SIS if not properly designed and operated. This advisory presents an example of how increasing the instrument air header
pressure caused most of the shutoff valves in the plant to fail in a dangerous state. A sobering reminder of the
importance of utilities and the reality of common cause failures.
CA - 06 - Instrument Air Pressure Safety Issues (PDF - 25k)
CA - 05 - Breakdown Maintenance Not Allowed by OSHA
In order to have an effective program for mechanical integrity of safety instrumented systems it is essential
that equipment is only employed during its "useful life". Some operating companies current practices do not
include replacement of 'shorter' useful life components, such as solenoid valves, until the device fails. Operating
companies should consider modifying their programs to ensure that these devices are replaced before they fail,
based on compliance guidance from OSHA.
CA - 05 - Breakdown Maintenance Not Allowed (PDF - 24k)
CA - 04 - Continuous vs. Demand Mode Safety Instrumented Functions
The most recent edition the ANSI/ISA S84.00.01-2004, Functional Safety: Safety Instrumented Systems for
the Process Industry Sector, establishes alternative design procedures for Safety Instrumented Systems (SIS) depending on the
expected frequency of a demand condition being placed on a Safety Instrumented Function, or SIF. Designers of Safety Instrumented
Systems refer to these different applications as either Continuous Mode or Demand Mode SIF.
CA - 04 - Continuous vs. Demand Mode SIF (PDF - 70k)
CA - 03 - Coker Safety Initiative
A number of refinery have undertaken initiatives to improve the safety of Coker operations. These initiatives
have also been closely followed by regulators who have also issues guidance documents that highlight the hazards of Coker
operation and provide recommendations for improving their safety...
CA - 03 - Coker Safety Initiative (PDF - 339k)
CA - 02 - Instrumentation and Control Mechanical Integrity Programs
There has recently been a large amount of interest in the mechanical integrity programs that are employed for
instrumentation and control systems at refineries and chemicals plants. The focus of these reviews has been to ensure that all
instrumentation is covered under an appropriate testing and maintenance program, and that these programs are consistent from site
to site...
CA - 02 - Instrumentation & Control Mechanical Integrity Programs (PDF - 82k)
CA - 01 - EPA Risk Management Plan Update and Resubmission
In 1999, over 14,000 industrial sites were required to submit Risk Management Plans to the Environmental
Protection Agency. These plans are required to be updated every five years, and the five year anniversary of the first submissions
falls on June 21, 2004, only a few months away...
CA - 01 - EPA Risk Management Plan Update & Resubmission (PDF - 70k)
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