Global Best Practices in Safety
Contents
• Why do we need Safety and Risk management?
• Companies benefitted from Chilworth experience.
• Some major disasters
• Hazard control, how?
• Global practices for Safety and Risk Management
• Project stages and Risk management
• Food for thought.
• Questions?
Why Do we need Safety?
• Don’t wait for a major accident to identify need to improve major
hazard management.
• Need to learn lessons from accidents (Hindsight) but don’t rely on
this approach
• Manage risks via Foresight rather than Hindsight ie be proactive
rather than reactive.
Our Clients
Wide spectrum of Industrial
Sectors…..
Pharmaceuticals
Petrochemicals
Oil & Gas
Refinery
Agrochemicals
Specialty Chemicals
Textiles
Fertilizers
Paint & Coatings
Engineering
Building (Hotels, Hospitals,
Corporate)
Our Clients
“More than 800 valued
clients world over…..”
“More than 200 valued
clients in India…..”
“Many of them Fortune
500 Companies…..”
BP Texas Refinery
• BP AMOCO Refinery is on 1,200
acres with 30 refinery units and
is 71 years old.
• 1800 people work at the refinery
plus contractors
• It is BP’s largest plant, and the
USA’s third largest refinery,
processing 460,000 barrels of
crude oil/day, around 3% of US
gasolene supplies
BP Texas Refinery – The Aftermath
Bruncefield, UK
Piper Alpha
Piper Alpha – After the fire
It cant happen to us!!!
Texas City Explosion – 23 March 2005
• Direct Root Cause: Level Indicator Failure and
High Level Alarm failure
Buncefield UK Explosion – 11December 2005
• Direct Root Cause: Level Indicator Failure and
High Level Alarm failure
Hazard Controls
• Prevention Controls • Mitigation Controls
– Elimination – Ignition Prevention
– Substitution – Alarms and Procedures
– Engineering – Mitigation
– Alarms & Procedures – Emergency Response
– Passive Devices – Prevention of “Escalation to
– Prevention of “Escalation other vessel”
from other incident”
Layers of Protection Analysis (LOPA)
COMMUNITY EMERGENCY
RESPONSE
Emergency Scenario PLANT EMERGENCY
Training RESPONSE
MITIGATION
Fire Protection SYSTEM
PSV’s PREVENTION SYSTEM
SIS
RBI
BPCS
Process
Alarms PROCESS DESIGN
Operations
Supervision PROCESS
Operating vs Design Verification
HAZID
• Hazard identification at various stages of project
• Brainstorming with the use of guidewords
• Prompt study team members to identify hazards
• HAZID typically focuses on plant layout drawing, as it
aims to identify intrinsic hazards.
• HAZID is useful at an early stages of a new design so that
all potential hazards can be taken into account.
• HAZID is also the technique of choice for identifying
hazards as the first stages of demonstration of ALARP.
HAZOP
• The basic premise of HAZOPS is:
All hazardous material incidents are instigated by a deviation from
the desired operating state or condition.
• If we can predict all deviations and analyze them before we operate
a new process then we can head off the undesired consequences.
Forewarned is Forearmed
Quantitative Risk Assessment (QRA)
HAZARD IDENTIFICATION METHODS:
System description
- Process hazard checklist
- Hazard survey: DOW index Hazard identification
- HAZOP hazard & operability study Scenario identification
- Safety review
RISK ASSESSMENT: Accident Accident
- What can go wrong & how ? probability consequences
- What are the chances ?
Risk determination
- Consequences ?
EXTREMES risk &
N
hazard Modify design
- Low probability
acceptable
- Minimal consequences ? Y
Accept system
Safety Integrity Level (SIL)
• Safety Integrity Level (SIL) is a statistical representation of SIS when
demand occurs.
• But in its simplest form it assesses:
– How high is your risk of an “undesired event” ?
– What level of protection do you need?
– Do you have the required level of protection in your design?
• Typical Safety Instrumented Systems (SIS):
– ESD
– F&G Detection System
– Blowdown System
Escape, Evacuation & Rescue Analysis (EERA)
EERA comprises following two elements, with their objectives:
• A goal analysis – The objective of the goal analysis is to confirm the
adequacy of the EER facilities and arrangements, and identify any areas
of weakness.
• An evacuation time analysis – The objective of the evacuation analysis is
to assess if the muster area and evacuation facilities are able to endure
local fire events for the period required for the POB to evacuate.
EERA Goals
There are seven (7) EERA goals which will be assessed in the EERA report and
these goals are listed as below:
• Goal 1 (Alarm);
• Goal 2 (Escape);
• Goal 3 (Muster);
• Goal 4 (Decision to Evacuate);
• Goal 5 (Primary Means of Evacuation);
• Goal 6 (Secondary Means of Evacuation); and
• Goal 7 (Rescue)
Emergency Systems Survivability Analysis
(ESSA)
• To assess criticality of emergency systems
• To determine if emergency system sub-components are fail-safe;
• To determine whether emergency system sub-components are vulnerable to
fire and explosion events;
• To determine whether emergency system sub-components have redundancy;
and
• To recommend risk reduction measures to increase the survivability of
emergency systems, which are vulnerable to Major Accident Events, and are
neither fail-safe nor have redundancy.
Safety Management System (SMS)
• The SMS - identify, select, define, implement, monitor, maintain,
review and improve the range of control measures
• Errors, deviations and breakdowns in control measures and
corresponding parts of the SMS are tracked
• Performance standards must be used to facilitate this process.
• Consistent with safety culture, company’s overall business
management system
Behaviour Based Safety (BBS)
• BBS is a process approach to improving safety performance by
helping workgroup to,
– Identify safety-related behaviours that are critical to
performance
– Gather data on workgroup safety excellence
– Provide ongoing, two-way performance feedback
– Remove safety barriers to continuous improvement
BBS - Risk Perception
• Why are people unimpressed by safety risks?
– Risk taking – a matter of choice
– Familiarity breeds complacency
– We get what we deserve – work place injuries are fair
– Risky work practices are accepted and becomes the NORM
Behaviour Safety is based on:
• Finding out what people are doing that leads to incidents and
stopping them doing it. Or…
• Finding out what people are doing to avoid incidents and getting
everyone to do it
• Behaviour (unlike attitude) is visible, measurable and can be
directly influenced
Safety at various Stages
• Planning Stage
• Design stage
• Construction
• Pre commissioning / Commissioning
• Operations stage
• Decommissioning and abandonment.
Planning Stage
Prevention of accidents should be the goal:
• Design options (use of chemicals, technology etc)
• Layout review (various locations and configurations)
• Project HSE Review (PHSER)
• Hazard Identification (HAZID)
• Risk Register
Design Stage
Adequate Design suitable for operations:
• HAZID (Hazard Identification)
• HAZOP (Hazard and Operability Study)
• QRA (Quantitative Risk Assessment)
• SIL (Safety Integrity Level)
• SCE/PS (Safety Critical Elements / Performance Standards)
• Dispersion
• EERA (Escape, Evacuation and Rescue Analysis)
• ESSA (Emergency Systems Survivability analysis)
Design Stage (continued)
• Project HSE Review (PHSER)
• ALARP
• RAM
• Safety Case / COMAH
• Fire Water network
• Fire Fighting System and extinguishers
• Emergency Response Plan
• Risk Register
Construction / Commissioning Stage
Safe Construction / commissioning and fit for operation:
• HAZID
• HAZOP (update, as built)
• Construction Safety
• Subcontractor Safety
• Transport Safety
• Project HSE Review (PHSER)
• Constructability Study
• Risk Register
• BBS
Operations Stage
Safe operation with no incidents:
• Risk Based Inspection (RBI)
• Reliability Centred Maintenance (RCM)
• Subcontractor Safety
• Transport Safety
• Risk Register
• SCE/PS update
• Operations Safety Case
• Safety / PSM / SMS Audits
• BBS
Decommissioning / Abandonment Stage
Safe abandonment and disposal:
• HAZID
• QRA
• Project HSE Review (PHSER)
• Risk Register
Food for thought
To protect against major accidents and consequential losses, there are generally
considered to be three layers (or types) of protection:
Asset Integrity – 3 Primary Protection Layers
facilities – processes – people –
supply & maintenance of management systems, organisation, roles &
plant, hardware, processes, procedures and responsibilities,
software, control systems other work systems to knowledge, training,
etc, along with their identify, control and experience, resource
design and layout to mitigate risks and to levels and capability
eliminate, control or improve operational along with the mindsets
mitigate risks and performance & behaviours of
improve productivity personnel
throughout the asset
lifecycle
Decreasing Reliability of Protection
Behaviours have a key role in improving Asset Integrity
Both Personal Safety and Asset Integrity Safety issues can be
addressed through BBS
Questions??
Contact
Jitendra Kumar, Vice President
+91 9811340933 jitendra@[Link]
CHILWORTH TECHNOLOGY P. LTD.
Muskaan Complex, B-2, Plot No. 3,
Vasant Kunj, New Delhi - 110070
Tel: + 91 11 26136979; Fax +91 11 26135979
[Link]