Overfill prevention processes (OPPs) act as a subset of the safety management system (SMS) that companies use to maintain the health of their workers and equipment. SMS, broadly defined, encompasses all the safety concerns for any processes, equipment, and systems within an organization or facility.
OPPs help organizations reduce the potential for environmental near-misses, incidents, and disasters by giving all workers an action plan to follow in case of excess fluid buildup. These systems automatically monitor fluid levels and pressures in holding tanks and alert operators to potential issues.
Benefits of Installing OPPs
OPPs offer organizations peace of mind, meaning that your team can dedicate more resources to essential processes and leave monitoring to the system. When you implement an OPP, you can expect a streamlined quality control process that allows you to better monitor facility health.
OPPs prioritize overfill protection. The tank filling process is comprehensively addressed through a variety of means, including:
· Risk assessment
· Risk management
· SMS/OPP requirements
Leveraging OPPs also means that the tools required for the identification of potential and actual hazards are provided and supported by management. Other tools critical to locating risks before they evolve into hazards must also be provided by management with full support.
Under OPPs, near-misses and incidents receive systematic analyzation, during which the root causes of overfills are determined and addressed. Maintenance and operations procedures, process equipment, and compliance measures are also constantly evaluated with the goal of actively preventing and controlling overfills.
OPPs ensure that all of an organization’s employees are committed to preventing, managing, and controlling overfills. This includes both management and regular employees and covers everything from behaviors and attitudes to values, skills, and actions
Following the implementation of an OPP, resources should always be properly allocated. The personnel responsible for managing and operating these resources (and tank facilities as a whole) become more knowledgeable and trained in the basic principles of overfill protection, which is critical to product and plant safety alike.
Processes from Endress+Hauser
Endress+Hauser offers high-quality OPP systems designed to enhance your facility’s fluid-processing capabilities without sacrificing machine health. A few of our most popular offerings include:
Overfill Prevention System SOP300
Designed to accommodate up to 128 tanks, the SOP300 features an automated proof-test sequence and complies with both API2350 and WHG. The system can function as an automatic or manual system and boasts several useful features:
· Capable of detecting signals in the base of the tank triggered by factors such as:
o Pump protection
o Issue alarms/alerts
· Automatically activates signaling elements and outputs relevant messages on a display when:
o Fluids overshoot or undershoot defined levels
o A leak is detected
Overfill Prevention System SOP600
Ideal for use as an automatic or manual system, the SOP600 is API2350 and WHG compliant. The system can accommodate as many as 16 tanks and features a built-in automatic proof-test sequence. The SOP600 offers facilities a host of benefits, including:
· Type certification up to SIL3 according to IEC 61511
· Ability to detect signals in the base of the tank caused by:
o Pump protection
o Issue alarms/alerts
· Activates signaling elements and shows messages on a display in cases when:
o Limit values are violated
o Leaks are detected
OPP is a proven risk-management process that ties all the elements of an organization together, both laterally and vertically. It’s critical to keep in mind that OPPs can be effective only if management and employees alike accept and support a safety culture that does not tolerate overfills.
Quality Safety Systems at Endress+Hauser
If you would like to learn more about how OPPs can benefit your business and improve the safety of your team, take a look at our API 2350 Guidebook on Overfill Prevention & Tank Gauging today.