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Plant Safety

Plant Safety

Industrial Safety Management for Your Plants and Processes

Safety deficits in refinery plants, nuclear power plants, and petrochemical plants can threaten the environment and the health of employees and local residents. In the event of damage, downtime and loss of production can incur substantial added costs. We can provide complete safety verification services throughout the entire life cycle of your refinery, petrochemical and power plants. Our experts are here to assist you in all matters of plant safety, from planning the plant to damage control. We help you implement and comply with statutory regulations governing industrial safety, surface water protection, environment, nuclear engineering, and hazardous goods.

We can help you ensure the safety of your plant during operation as well as secure process safety. As part of the process safety management procedures, our experts conduct assessment of process safety management system, process hazard analysis, in-depth quantitative risk assessment and mechanical integrity assessment. TÜV Rheinland guarantees the reliability and industrial safety of your plants through safety integrity checks of instrumented systems, damage diagnosis or failure analysis, explosion-proof safety assessments as well as a wide range of safety verification and industrial safety management services.

Our plant safety experts offer you a wide range of services to help you implement operational safety - PT and environmental protection measures throughout the entire life cycle of your plants.

Benefits at a Glance

With the support of our plant safety experts, you can:

  • Fulfill your operator responsibilities through legally sound implementation of statutory provisions.
  • Optimize your processes and establish a viable plant and process safety management system that supports you in reliably preventing incidents.
  • Identify the degree of compliance and level of necessary improvement required for your plant’s process safety management system.
  • Achieve compliance with statutory regulations and international standards of industrial safety.
  • Take advantage of our international network of experts and one-stop shop service.
  • Reinforce the confidence of employees, local residents, and the general public in the safety of your plants.

Please feel free to contact us at TÜV Rheinland to learn more about how our plant safety and process safety management services can benefit your company.

Our Range of Plant Safety and Process Safety Management Services

TÜV Rheinland provides a wide range of services to meet applicable industrial safety standards throughout the phases of your plant´s life cycle.

During the engineering, design and construction phases, we:

  • Develop concepts for incident prevention.
  • Establish and adapt safety management systems in compliance with the requirements of hazardous incident regulations.
  • Assess your process safety management (PSM) systems.
  • Conduct process hazard analysis (PHA) and quantitative risk analysis (QRA).
  • Prepare and review safety reports.
  • Provide design review of your system equipment and safety instrumented system (SIS) assessment.
  • Conduct safety engineering reviews according to the emissions control regulations (§29a Bundes-Immissionsschutzgesetz (BImSchG)).
  • Provide surveillance during the construction of your power plant and the installation of your equipment and systems.

During plant operation and maintenance, our experts provide you with:

  • Safety engineering plant inspections.
  • Project management.
  • Third-party inspection.
  • Maintenance concepts.
  • Preparation of dispersion calculations.
  • Risk analyses based on recognized methods such as HAZOP (hazard and operability) and PAAG (stands for Prognose, Auffinden der Ursache, Abschätzen der Auswirkungen, Gegenmaßnahmen – German HAZOP method).
  • Support for safety integrity level (SIL) classification.
  • Preparation of explosion protection documents .

To prevent disasters or in the event of damage, we offer:

  • Risk assessment and safety engineering evaluation.
  • Non-destructive testing services.
  • Damage investigations.
  • Disaster prevention - PT .
  • Inspection interval extension.

Assessment of Your Process Safety Management System

A plant is an elaborate structure where personnel and technology meet within a complex facility. We have extensive experience in process safety management and can therefore help you implement an optimized system to ensure the safety of your plant and processes, as well as assess and ensure the fitness-for-service of your plant equipment in specific conditions.

Thanks to a strong management leadership commitment, extended experience in safety culture and a deep knowledge of management performance indicators, our experts provide you comprehensive consultation services for the 14 elements of Process Safety Management as defined by the US Occupational Safety and Health Administration (OSHA) and help you set up all measures required by each of the 14 element standards.

For your technologies:

  • Develop and maintain process safety information to identify process hazards as well as assess equipments and technologies used in the process.
  • Perform process hazard analysis (PHA) to determine workplace hazards, including the identification of potential sources of accidents and risks and the evaluation of the safety effects on your personnel.
  • Implement operating procedures consistent with the process safety information, providing clear instructions to conduct safe operations and activities.
  • Establish procedures for the management of change in technology, process chemicals, equipment or facilities in your plant.

For your personnel:

  • Encourage employee participation and develop an action plan upon consultation of personnel and their representatives.
  • Provide safety and operating information as well as employee training in safety and operating procedures, emphasizing hazards and safe practices.
  • Ensure that contractors and contract employees are also provided with the relevant and appropriate training and process information.
  • Conduct incident investigation for any event that resulted or could have resulted in a major accident, and let operating personnel review all findings of the investigation.
  • Provide your employees and contractors with trainings in emergency response procedures.
  • Conduct compliance audits to assess the effectiveness of your process safety management and verify that developed procedures and practices are being followed.
  • Make available any information needed to comply with PSM requirements to your personnel (employees and contractors). This, however, is not a trade secret, and you cannot require employee non-disclosure of the information provided.

And for your facility:

  • Implement all fire prevention - PT and protection requirements required by the OSHA regulation prior to the beginning of hot work operations to receive your hot work permit.
  • Ensure mechanical integrity by establishing maintenance systems and processes for your equipment, including written procedures, employees training and equipment testing and inspection. Conduct pre-startup safety reviews for all modified or newly installed equipment within your facility.

Our Test Standards

  • Hazardous incident regulations
  • Immissions control regulations (Bundes-Immissionsschutzgesetz (BImSchG))
  • Industrial safety and health regulations (Betriebssicherheitsverordnung (BetrSichV))
  • Water management regulations (Wasserhaushaltgesetz (WHG))
  • Occupational safety and health regulations
  • Plant-specific standards

Risk and Hazard Analysis Methods

HAZOP stands for Hazard and Operability. This method analyzes risks consists through examination of processes and operations to identify and evaluate problems that may affect equipment, imperil personnel or impede efficient operation of the plant.

PAAG, the German abbreviation for “Prognose, Auffinden der Ursache, Abschätzen der Auswirkungen, Gegenmaßnahmen“, is a risk analysis method. Analysis is conducted in four steps made up of a risk forecast, determination of the causes and sources of risks, an evaluation of the potential consequences and the proposition of measures to prevent these hazards.

Process Hazard Analysis (PHA)
PHA consists of a series of assessments and evaluations of potential hazards which may arise from industrial processes. This type of analysis enables you to improve plant safety and reduce consequences in the event of damage.

Quantitative Risk Analysis (QRA)
The Quantitative Risk Analysis is a method which enables you to determine a quantitative value of the assessed risk or hazard. In addition to the risk, it also evaluates the potential loss as well as its probability to occur. This method is extremely useful in providing beneficial forecasts, especially during the design phase of a project.

Layers of Protection Analysis (LOPA)
The Layers of Protection Analysis is a method used to assign your plant a safety integrity level (SIL). In other words, this technique enables you to determine a relative level of safety in order to implement measures to reduce on-site risk ensuring both employee and operational safety.

Risk Based Inspection (RBI)
The risk based inspection is a process which helps to identify and assess potential risks in plant equipment. It enables you to define the plant's level of risk in order to further develop inspection plans to prevent hazards on site.

Corrosion Loop
Corrosion loop is a systematized analysis loop conducted during a risk based inspection. The system of corrosion loop enables to assess both the probability and possible consequences of failure.

Reference Cases

pdf Reference Case: Global Business Power Corporation, Philippines 98 KB Download
pdf Reference Case: Inspection Services Saudi Shutdown Project 162 KB Download
pdf Reference Case: Merck DISMA, Germany 652 KB Download
pdf Reference Case: Risk Analysis Petrobrazi Refinery, Romania 634 KB Download
pdf Reference Case: Risk Based Inspection Program Oil Refinery Kuwait 120 KB Download
pdf Reference Case: Risk Based Management, Lithuania 99 KB Download
pdf Reference Case: Safety Assessmemt - Formosa Plastics, Taiwan 642 KB Download

Our Services

pdf Explosion Protection 445 KB Download
pdf Industrial Services 4 MB Download
pdf Services for Power Plants 1 MB Download
pdf Services for the Oil & Gas Industry 5 MB Download
pdf Industrial Inspection Services 876 KB Download
pdf RBI Service Sheet 563 KB Download

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