In many cases, Management of Change (MOC) programs are overly burdensome and could be ineffective. The application of MOC at the early stage of process design is simpler and easier compare to at later design stages. MOC methodology should be applied to engineering design deviations and variances, as well as to preplanned changes. An improper relief header design can lead to outcomes that pose a significant threat to the operators and the equipments in the immediate vicinity of the failure location.

Oleh : Darmawan Ahmad Mukharror

Process Safety Engineer, VICO Indonesia Co Ltd. LLC.

Abstract –

In many cases, Management of Change (MOC) programs are overly burdensome and could be ineffective. The application of MOC at the early stage of process design is simpler and easier compare to at later design stages. MOC methodology should be applied to engineering design deviations and variances, as well as to preplanned changes. An improper relief header design can lead to outcomes that pose a significant threat to the operators and the equipments in the immediate vicinity of the failure location.
This paper highlights the application of MOC during engineering design and construction, the use of available technology to support MOC, and how MOC application helps to execute the revised design. The improper design of relief header is also presented as the case study.

Keywords: management of change (MOC), change, engineering design deviation, relief header design, revised design

1. Change and Management of Change

First introduced formally by nuclear power industry, Management of change (MOC) has been quickly spread to the defense energy [1]. The meaning of MOC refers to the making of changes in a planned and managed or systematic fashion. The intention of MOC is to implement new methods and systems more effectively in an ongoing organization. The changes to be managed lie within and are controlled by organization. Hence, the second meaning of managing change is the response to changes over which the organization exercise little or no control.
MOC procedures have stolen attention due to the introduction of requirements within the new OSHA 1992 and EPA 1998 process safety management regulations in US. Recently, ISO 9000 quality initiatives have provided future significance to the need for process change control management. While many firms applied MOC only to equipment and field operational procedures changes, some big chemicals producers are also applied MOC on personnel.
The absence of MOC has resulted in several catastrophic failures. One of the major process safety disaster to have identified MOC as a root cause was the Flixborough accident in 1974. The UK royal commission recommended that chemical plants to establish MOC procedures to avoid such catastrophic accidents. It can be said that almost every major accidents can be correlated to a change that was not subjected to a proper safety review as required by MOC [2, 3]
There are two kinds of changes in the oil and gas processing facilities: permanent and temporary. Whenever a change that will become permanent is made in plant or in a process, management systems and procedures must be in place to assure that hazards and risks have been identified and proper precautions have been taken to minimize those risks. Temporary changes should have a prescribed time limit and should be properly documented. Renewal of temporary change time limitations must be reviewed to assure that adequate safeguards are being maintained.

2. Engineering Design Deviation

It is essential that such changes do not result in deviations that lead to operation outside the established safe operating limits. Thus, during the lifetime of a single project, it may be normal to
Establish several changes prior to the plant decommissioning.

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