From theory to practice: Implementing safe operating limits in major hazard facilities

Abstract Defining safe operating limits of critical operating parameters, reviewing their validity periodically, and recording any exceedance (if any) are vital for the safe operation of the chemical plant, especially for major hazard installations. Despite this, users often encounter challenges such as: (a) difficulty in accurately identifying their limits, (b) uncertainty in the process of determining appropriate limits, and (c) setting limits too close to or too far from the normal operating or mechanical design thresholds of the equipment. This, in turn, would lead to reduced operational flexibility of the equipment or increased safety concerns due to insufficient margins. This paper briefly discusses lessons learned from industrial accidents related to safe operating limits, how safe operating limits are linked to regulatory assessments, challenges in defining appropriate limits, and the methodology for establishing them.