Safety, Legislation & Cost Effectiveness

MECH68022 Safety, Legislation & Cost Effectiveness 15 Semester 2 Postgraduate Taught Level 7 Paul Wheelhouse Unit coordinator 1 FHEQ level (Framework for Higher Education Qualifications) ' Masters/Integrated Masters P4 ' European Credit Transfer & Accumulation System Rating : 7.5 This unit covers the safety, legislation, standards and cost effectiveness requirements for asset management and maintenance in an industrial environment. It has seven sections which are listed below.<ol> <li>Process Safety</li> <li>Legislation, Regulations, Codes of Practice, & Standards </li> <li>Risk Management Techniques </li> <li>Asset Integrity Management </li> <li>Electrical Safety </li> <li>Financial importance of asset management & maintenance </li> <li>Costing for maintenance & asset management</li></ol> This unit covers the safety, legislation, standards and cost effectiveness requirements for asset management and maintenance in an industrial environment. It has seven sections which are described below.Process Safety Safety recap: moral, legal and business imperatives: price of getting it wrong with case study examples. Process safety system definition and then examples from BP, DuPont & PDO. Assessment of process safety maturity with ISRS model from Det Norse Veritas. Common features of safety, health, environment & quality systems. Learning lessons. Human error. Just culture. Behavioural safety. The DuPont STOP system. Audits, Inspections & Tool box talks.Legislation, Regulations, Codes of Practice, & Standards Sources & Hierarchy of EU Law. General Principles of Union Law. EU Sources of Law. Primary legislation. Secondary legislation. Directive 89/391/EEC - OSH "Framework Directive." The General Principle of Prevention in the Directive. Giving appropriate instructions to the workers. Duties of Employers. UK Safety Laws & Regulations. Civil & Criminal Law. Health and Safety at Work Etc. Act 1974 with its implications and duties on employers and employees. Case study examples of fines, improvement and prohibition notices Reverse burden of proof. The test for reasonably practical and ALARP. Safe plant and safe systems of work. Safe handling, storage, maintenance and transportation of work articles and substances. A safe place of work with safe access and egress. A safe working environment and adequate welfare facilities. Importance of Industry Associations. The Safety Assessment Federation. The Engineering Equipment & Materials Users Association. Maintenance Regimes and some relevant Regulations. Management of Health and Safety Regulations. Provision and use of Work Equipment Regulations. Lifting Operations and Lifting Equipment Regulations. Workplace (Health, Safety and Welfare) Regulations. Material Safety Data Sheets and their uses. Control of Substances Hazardous to Health (COSHH) inclusions and exclusions. Control of Major Accident Hazard (COMAH). Seveso II Directive. Preparing Process Plant for Work. Permit to Work Systems. Management of Change and its Development following the Flixborough disaster in the UK in 1974. Plant modification system for all hardware and software changes. Confined spaces Regulations. Noise at work Regulations. Introduction to some relevant ISO 45001, OHSAA 18001, ISO 14001, ISO 9001, & ISO 55001.Risk Management Techniques Risk Management and ISO 31000. Risk Control Hierarchy  following Directive 89/391/EEC. Risk Assessment - The Risk Matrix. Keeping a sense of proportion when conducting risk assessments with good and bad examples. ALARP. Case study example of five-step process risk management process advocated by UK HSE. Introduction with examples and exercises of a wide variety of risk management techniques. HAZID, HAZAN, HAZOP. Quantitative predictive modelling. Scenario modelling including choosing appropriate criteria. Fault trees & event trees. Chained events. Bow Tie. What if? The Swiss Cheese model by Reason. IEC 61511 and Safety Integrity Level Layers of protection analysis (LOPA) and its use in specifying requirement for instrument protective systems. Failure Modes & Effects Analysis. Reliability Centred Maintenance. Asset Integrity Management Definition of integrity. Design standards and what they require. Development of risk-based inspection, RBI. API 570 & 571.  Scope of equipment for risk-based inspection. Case study examples of the reported benefits of RBI. Where next with RBI principles?Electrical Safety Protecting people and property from danger. Example of the implications of fault levels in electrical systems. UK Electrical Regulations. Electricity Safety, Quality & Continuity Regulations 2002. BS 7671 or the IET Wiring Regulations 18th Edition. Explanation of the different forms of protection in electrical systems. Testing of protective systems with example guidance from the UK HSE on potable equipment. Explosions of gases and dusts and the implications for electrical equipment. Hazardous are classification with an exercise. ATEX regulations and their implication for equipment selection, inspection and maintenance.Financial importance of asset management & maintenance How assets affect profitability, cash flow and return on investment. A case study example using the DuPont model for calculating annual return on investment. How asset performance and maintenance affect both the tangible and intangible value of an organisation. The link between asset performance and lean illustrated with a case study example. The implications of lean manufacturing in terms of reliability improvement, life cycle costing and organisational risk. The models for value added maintenance and asset management with examples illustrating their use. Case study example of using account information to highlight value adding improvement opportunities. The approvals process for investing new capital within an organisation. Four commonly used investment approval criteria together with their pros and cons: NPV, IRR, minimum life cycle cost and payback. How to make a case for a new investment within an organisation. Toyota case study illustrating the value coming from its on-going continuous programme. A case study example showing the use of six-sigma as part of a continuous improvement project.Costing for maintenance & asset management Costing for various asset and maintenance activities. Introduction to the concept of the total cost of maintenance including visible and hidden costs. Lifecycle costing its pros, cons and implications. Example of life cycle costing from a utility company, a glass company and a family car. Costing for investment and improvements. Using unit costs and the parametric approach. Dealing with uncertainties and contingencies. Using the critical path approach for a project in combination with PERT technique. The optimum use of contingency funds to minimise total project costs. To discuss the vital parts which safety, legislation & cost-effectiveness play in all aspects of maintenance & asset management. Explain / describe the principles of costing. Describe how assets generate value. Understand how an organisation can maximise its performance in safety, health, environment & quality areas. Explain / describe how assets generate value by being put to work Cost a variety of asset management & maintenance activities Take adequate account of safety, legislation & cost-effectiveness in all other MSc modules & then on-going careers This unit covers the safety, legislation, standards and cost effectiveness requirements for asset management and maintenance in an industrial environment. It has seven sections which are listed below.<ol> <li>Process Safety</li> <li>Legislation, Regulations, Codes of Practice, & Standards </li> <li>Risk Management Techniques </li> <li>Asset Integrity Management </li> <li>Electrical Safety </li> <li>Financial importance of asset management & maintenance </li> <li>Costing for maintenance & asset management</li></ol> This unit is taught online via Blackboard with one full day of teaching. 1 Written exam 50% 3 Report 50% Provided online via the Blackboard system. MECH69001 Asset Management Strategy & Organisation Co-Requisite Compulsory MSc Reliability Eng/Asst Mgmt MSc Reliability Eng/Asset Mgmt PGDT Taught Component Mandatory MSc Reliability Eng/Asset Mgmt MSc Reliability Eng/Asset Mgmt PGDT Taught Component Mandatory N Redgrave’s Health & Safety 9th Edition by Jonathan Clarke 2016 ISBN 9781405781329What Went Wrong by Trevor Kletz 4th Edition 1999 ISBN 9780884159209Value Driven Maintenance by Mark Haarman & Guy Delahay 2003 ISBN 9799080827027 Lectures 8 Project supervision 50 Tutorials 22 0 70