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Threat Scenario
EML (Effective Access Controls in Place)
1. Large truck bomb detonated
at access gate X 25,000,000
US$ 22,000,000

2. Car bomb detonated inside

main process area X 20,000,000
US$ millions

15,000,000

3. Bag bomb hand-carried in to 10,000,000

process area and detonated

500,0000
4. Explosion following deliberate release of
LPG from storage bullets located in
main site
0
Scenario 3 Scenario 4

Current Controls Threat Scenario

t Earth berm around side
t 24/7 armed access control/search engine
t Hardened search and hold areas
t Blast walls at access points
t Restricted/dedicated ‘onside only’ vehicles kept inside perimeter
t Sniffer dogs
t Personnel ID and vehicle access control systems
t Vetting and background checks of local staff
t Permit system for zoned work areas on site

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Introduction
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5-"X%$7687$%9/"$<%6+%,A$-5%<-00$5$+,%9/.X156#+<";%
$=*$5-$+.$";%A-",65-$"%/+<%.64*/+R%.#8,#5$"2%^65K/5<%
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$=.A/+1$2
Meeting of two giants
BK6%60%,A$%46",%"#..$""0#8%5$0-+-+1%/+<%*$,56.A$4-./8%
.64*/+-$"%-+%/88%60%D"-/%/5$%Fg%E+$51R%60%g65$/%/+<%
^6546"/%L8/",-."%H56#*%c^LHd%60%B/-K/+2%C6,A%/5$%
,A$%8/51$",%.64*/+-$"%-+%,A$-5%5$"*$.,-7$%.6#+,5-$"%
-+%,A$%$+$51R%/+<%*$,56.A$4-./8%9#"-+$""2%C6,A%/5$%
D"-/%F/0$,R%E=.A/+1$%J%G6""%I6+,568%3$K"8$,,$5
YueFeng Chen
h-.$%L5$"-<$+,%
S/5"A%H869/8%E+$51R%O-"X%E+1-+$$5-+1
R#$0$+12.A$+Q4/5"A2.64
S/5"A%.8-$+,"2%!+%S/R%&((`%S/5"A%H869/8%E+$51R%O-"X%
E+1-+$$5-+1%-+%F-+1/*65$%9$1/+%/+%$0065,%,6%.6++$.,%
,A$"$%,K6%.64*/+-$"%-+%/+%600-.-/8%4/++$5%-+%/%"/0$,R%
$=.A/+1$%,A/,%K6#8<%-+7687$%7-"-,"%,6%$/.A%.64*/+RV"%
4/T65%0/.-8-,-$"%06886K$<%9R%0654/8%/+<%-+0654/8%
<-".#""-6+"%5$1/5<-+1%5-"X%/+<%"/0$,R%-""#$"2%B6*%
4/+/1$4$+,%60%96,A%.64*/+-$"%/15$$<%/+<%$0065,"%,6%
".A$<#8$%,A$%.56""%7-"-,"%9$1/+2%%%%%%%%%%
Fg%E+$51R%6*$5/,$"%6+$%60%,A$%8/51$",%5$0-+$5-$"%
cao(;(((%9*<d%-+%,A$%K658<%-+%/%.64*8$=%-+%>8"/+%
g65$/%,A/,%-"%-+,$15/,$<%0564%.5#<$%6-8%,6%*68R4$5"2%%
FgV"%5$0-+-+1%A-",65R%16$"%9/.X%,6%)`jo%KA$+%,A$%0-5",%
5$0-+$5R%",/5,$<%#*%-+%g65$/%/+<%/86+1%,A$%K/R%4#.A%
A/"%9$$+%8$/5+$<2%D0,$5%/%"$5-$"%60%/..-<$+,"%/96#,%
&(%R$/5"%/16;%,6*%4/+/1$4$+,%/"X$<%,A$%"/0$,R%
*$5"6++$8%,6%K65X%K-,A%-+"#5/+.$%5$8/,$<%5-"X%$+1-+$$5%
.6+"#8,/+,"%,6%-<$+,-0R%,A$%K$/X+$""$"%-+%,A$-5%"R",$4%
/+<%,6%5$"687$%,A6"$%-""#$"2%D%4/""-7$%#+<$5,/X-+1%
9$1/+%,6%-4*8$4$+,%,A$%9$",%*5/.,-.$"%-+%/88%/"*$.,"%
60%LFS%cL56.$""%F/0$,R%S/+/1$4$+,d2%BA$%$0065,%K/"%
K$88%06.#"$<%K-,A%,A$%68<$",%#+-,"%/+<%UK65",%0-5",V%
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06./8%*6-+,2%BA$%*56.$""%A/m/5<%/+/8R"-"%cLbDd%/"*$.,%
5$:#-5$<%,A/,%/88%68<$5%#+-,"%A/<%,A$-5%Lr!]"%cL-*-+1%
/+<%!+",5#4$+,/,-6+%]-/15/4"d%.6+7$5,$<%,6%D#,6%
ID]];%0-$8<e.A$.X$<%/+<%.655$.,$<%/"%/%*5$.#5"65%,6%
.6+<#.,-+1%4$/+-+10#8%LbD"2%D8"6%Fg%E+1-+$$5-+1%/+<%
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+#49$5%60%",/+</5<"%.6+"-<$5$<%-+<#",5R%9$",%*5/.,-.$";%
KA-.A%9$./4$%Fg%5$8/,$<%"/0$,R%/+<%$+1-+$$5-+1%
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9#-8,%,A$-5%0-5",%5$0-+$5R;%KA-.A%A/"%9$$+%6*$5/,-+1%
065%465$%,A/+%)(%R$/5";%/86+1%K-,A%,A5$$%K658<%"./8$%
+/*A,A/%.5/.X$5"%/88%-+,$15/,$<%-+,6%,A$%4/""-7$%S/-e
G-/6%!+<#",5-/8%L/5X;%-+%B/-K/+%,A/,%A/"%/+%-+7$",4$+,%
60%465$%,A/+%>Fn&(%9-88-6+2%F,/,$%60%,A$%/5,%GLH%
c8-:#$0-$<%*$,568$#4%1/"d%",65/1$%"R",$4"%"*$.-0-./88R%
10
<$"-1+$<%,6%5$<#.$%5-"X%K$5$%/<6*,$<%K-,A%GLH%-+% BA$%$7$+,%$+<$<%K-,A%/%8#+.A$6+%*/5,-.-*/,$<%-+%9R%
o(((%4N%46#+<$<%9#88$,"%/+<%B5/.,$9$8%5$05-1$5/,$<% .64*/+R%$=$.#,-7$";%96,A%156#*"%60%*/5,-.-*/+,"%K-,A%
,/+X"%#*%,6%a(;(((%4N%K-,A%4$/"#5$"%60%96,A%98/",% S/5"A%H869/8%E+$51R%O-"X%E+1-+$$5-+1%-+%/,,$+</+.$2%%
5$"-",/+.$%/+<%<6#98$%.6+,/-+4$+,2%^LH%/8"6%/<6*,$<%
/+<%-4*8$4$+,$<%5-"X%9/"$<%-+"*$.,-6+%*A-86"6*A-$"%
/+<%A-5$<%IA-+$"$e"*$/X-+1%"*$.-/8-","%,6%.6+"#8,%6+% Losing or learning?
,A$%*5615/44$"2%BA$%S/-eG-/6%!+<#",5-/8%L/5X%/8"6% >8,-4/,$8R;%,A$%$=*$5-$+.$%/886K$<%,A$%,K6%.64*/+-$"%
-+.65*65/,$"%"$-"4-.%<$"-1+"%*567$+%-+%,A$%g69$% K-,A%K$88%$",/98-"A$<;%9#,%7$5R%<-00$5$+,%.#8,#5$";%,6%
$/5,A:#/X$%-+%\/*/+%/+<%,A$%9$",%<$"-1+%*5/.,-.$"% "$$%/8,$5+/,-7$%K/R"%,6%/<<5$""%*5698$4"%.6446+%,6%
,6%5$"-",%K-+<",654%/+<%"$/%065.$"2%BA$%$4$51$+.R% 96,A2%D88%/15$$<%,A$%"/0$,R%$=.A/+1$%K/"%/%5$4/5X/98$%
0-5$%K/,$5%"#**8R%-+.8#<$"%"$7$+%*#4*%",/,-6+"%$/.A% "#..$""2%%
K-,A%/%./*/.-,R%60%)(;(((%1*4%<$8-7$5$<%/,%*56T$.,-6+%
*5$""#5$%,6%,A$%*8/+,%*$5-4$,$5"2%D8"6%"*$.-/8%4/+-068<"%
K$5$%-+",/88$<%,6%/886K%.6++$.,-6+"%60%8/51$%A6"$"%#*%
,6%)&%-+.A%<-/4$,$52%BA$%S/-eG-/6%!+<#",5-/8%L/5X%0-5$%
<$*/5,4$+,%-"%8-X$8R%,A$%",56+1$",%-+%/88%D"-/%K-,A%,A$%
./*/9-8-,R%,6%$=,-+1#-"A%`(%4$,5$%<-/4$,$5%086/,-+1%
5660%,/+X"%K-,A%/%"#+X$+%5660%.6+<-,-6+2%%%%%%%%%%%%

The exchange
!+%\#+$%&((`%Fg%E+$51R%"$+,%/%,$/4%60%,A5$$%,6%7-"-,%
^LH%.64*8$=%-+%S/-eG-/62%f0%"*$.-/8%-+,$5$",%K/"%,A$%
5$.$+,8R%*#5.A/"$<%,/+X%0-5$%0-1A,-+1%"R",$4%,A/,%
$+/98$"%$=,-+1#-"A4$+,%60%,A$%8/51$%.5#<$%,/+X";%,A$%
#"$%60%$/5,A%.67$5$<%G-:#$0-$<%L$,568$#4%H/"%cGLHd%
",65/1$%/+<%,A$%"*$.-/8%5$05-1$5/,$<%,/+X%<$"-1+"2%
D8"6%60%"*$.-/8%-+,$5$",%K/"%,A$%-4*8$4$+,/,-6+%/+<% !+%R6#5%$0065,"%,6%"A/5$%9$",%*5/.,-.$"%/+<%<5-7$%R6#5%
/**8-./,-6+%60%T69%"/0$,R%/+/8R"-"%-+%,A$%$8$.,56+-.% 5-"X"%<6K+;%A6K%*5$*/5$<%/5$%R6#%,6%K$8.64$%,A$%
*$54-,%,6%K65X%"R",$42%BA-"%K/"%06886K$<%9R%7-"-,"%,6% .64*$,-,-6+%-+,6%R6#5%6K+%A64$?%D"%Fg%/+<%^LH%A/7$%
B/-*$-%A$/<:#/5,$5"%/+<%<-".#""-6+"%K-,A%H56#*%EFb% 06#+<%6#,;%,A6"$%K-88-+1%,6%9$%95/7$%/+<%6*$+%,A$%
c$+7-56+4$+,;%A$/8,A%/+<%"/0$,Rd%4/+/1$5"%/96#,%A6K% <665"%A/7$%+6,A-+1%,6%86"$%/+<%4#.A%,6%8$/5+2%
$/.A%.64*/+R%*56,$.,"%,A$-5%*8/+,";%9#"-+$"";%*$6*8$%
/+<%,A$%$+7-56+4$+,2
Safety
!+%F$*,$49$5%&((`%^LH%"$+,%/%0-7$%4/+%,$/4%60%
Overhead fin-fan corrosion – emphasises need for
Snippet
5$*5$"$+,/,-7$"%0564%$/.A%60%,A$-5%4/T65%*56.$""%
multi-disciplinary involvement on all plant changes
.65*65/,-6+"%/+<%156#*%,6%7-"-,%Fg%E+$51R%-+%F$6#8%
A refinery experienced a leak from a CCR (Continuous Catalytic Reformer)
/+<%>8"/+%g65$/%KA$5$%6+$%60%,A$%8/51$",%5$0-+$5-$"% stabiliser overhead fin-fan. The leak occurred some 7½ years after the bundle
installation, whereas historical evidence was for a 12 year tube life and an
-+%,A$%K658<%-"%6*$5/,$<%9R%Fg%E+$51R2%f0%-+,$5$",%K/"% inspection had been scheduled for 8 years.
,A$%+$K%>Fn&%9-88-6+%^II%c08#-<-"$<%./,/8R,-.%.5/.X$5d%
Investigations showed that a previous change in catalyst had reduced the
*56T$.,%,A/,%K/"%"#..$""0#88R%.64*8$,$<%-+%N)%46+,A"2% chloride retention resulting in a lower pH in water and accelerated corrosion.
Fg%E+$51R%K/"%/98$%,6%-+.65*65/,$%/88%,A$%Fg%"/0$,R% Whilst a formal Management of Change procedure had been followed for the
catalyst change, the site’s Inspection Department had not been informed of
",/+</5<"%-+,6%,A$%<$"-1+"%K-,A6#,%-+A-9-,-+1%,A$% the change.

*56T$.,%".A$<#8$2%BA$%+$K%"-,$%K/"%7-"-,$<%K-,A%.86"$% Lesson: all relevant disciplines should be involved in plant changes

#*%5$7-$K"%60%,A$%98/",%5$"-",/+,%.6+,568%5664;%,A$%0-5$%
K/,$5%"R",$4;%,A$%*567-"-6+%60%$4$51$+.R%-"68/,-6+%
7/87$"%/+<%<-".#""-6+"%/96#,%A6K%,6%.6+<#.,%$00$.,-7$%
*56T$.,%5-"X%5$7-$K"2%D%",6*%K/"%".A$<#8$<%/,%Fg%H/"%
,6%5$7-$K%,A$-5%#"$%60%#+<$5156#+<%./7$5+"%065%GLH%
",65/1$2%BA-"%K/"%06886K$<%9R%<-".#""-6+"%/96#,%"/0$,R%
/+<%0-5$%*56,$.,-6+%",/+</5<"%/+<%,A$%-4*8$4$+,/,-6+;%
/**8-./,-6+%/+<%/#<-,-+1%60%*5615/44$"2%%%%%%%%%

D"-/%F/0$,R%E=.A/+1$%%J%G6""%I6+,568%3$K"8$,,$5 11
-A#'=0+#"+,).'=,+<)..1'0<'L3N')11#11D#"+',"'$,1@'D)")%#D#"+

Nigel Cairns
h-.$%L5$"-<$+,%
S/5"A%H869/8%E+$51R%O-"X%E+1-+$$5-+1
%
+-1$82K2./-5+"Q4/5"A2.64

>+0'2&=,+$"4&%.&G,$4;&H2%7,2&)"'$0F&I+4J&)"0+"''$+"0&#',-&%/#2+"'4&4%-'&*%--%"&
-+4#,J'4&U5'$,#%$4&-+0;#&-,J'&?;'"&,44'44+"0&S,.'#F&!"#'0$+#F&<'3'24&@S!<A8&,"1&4%-'&
6/'4#+%"4&#%&,4J&F%/$4'2.&?;'"&#$F+"0&#%&+1'"#+.F&;%?&$%7/4#&#;'&,44'44-'"#&+49

Introduction
BA$%+/,#5$%60%,A$%$+$51R%-+<#",5R%-"%"#.A%,A/,%
6*$5/,65"%K-88%1$+$5/88R%/88%A/7$%,A$%*6,$+,-/8%065%4/T65%
/..-<$+,";%6+%/..6#+,%60%,A$-5%A/+<8-+1%8/51$%768#4$"%
60%*6,$+,-/88R%$=*86"-7$%65%08/44/98$%4/,$5-/82%D"%*/5,%
60%,A$%5-"X%,5/+"0$5%*56.$""%K$%$+.6#5/1$%6*$5/,65"%
,6%4/+/1$%,A$"$%5-"X"%+6,%6+8R%,6%69,/-+%0/76#5/98$%
5-"X%*8/.$4$+,%-+%,A$%-+"#5/+.$%4/5X$,;%9#,%/8"6%,6%
$+"#5$%,A$R%.64*8R%K-,A%8$1-"8/,-6+;%4/-+,/-+%"6.-$,/8%
67$5"-1A,;%/+<%/8"6%065%"$80%*5$"$57/,-6+%*#5*6"$"2
!+%65<$5%,6%5$<#.$%,A$%8-X$8-A66<%60%"#.A%/+%$=*6"#5$;%
/+<%,6%8-4-,%-,"%-4*/.,;%,A$%6*$5/,65%K-88%*567-<$%
"/0$1#/5<"%-+%-,"%*56.$""$";%65%8/R$5"%60%*56,$.,-6+%
cGfLd;%,A/,%/<<5$""%96,A%-,"%A/5<K/5$%/+<%"60,K/5$%
0$/,#5$"2%E=/4*8$"%4-1A,%-+.8#<$%-,"%4/+/1$4$+,%60%
.A/+1$;%-+"*$.,-6+%/+<%$4$51$+.R%*56.$<#5$";%,A$%
8$7$8"%60%,5/-+-+1%/+<%7/8-</,-6+%60%-,"%6*$5/,-+1%",/00;%
/+<%/8"6%-,"%*56,$.,-7$%"R",$4";%"#.A%/"%*5$""#5$%5$8-$0%
65%,5-*%/+<%/8/54%"R",$4"2%D88%60%,A$"$%"R",$4"%K-88%A/7$%
/+%-+A$5$+,%5$8-/9-8-,R;%"6%-,V"%-4*65,/+,%,6%#+<$5",/+<%
KA/,%/""#4*,-6+"%,A$%6*$5/,65%A/"%4/<$%/96#,%
,A$-5%8/R$5"%60%*56,$.,-6+;%"6%,A/,%K$%./+%#+<$5",/+<%
KA$,A$5%,A$R%A/7$%,A$%5$:#-5$<%-+,$15-,R%,6%1-7$%
*56,$.,-6+%/1/-+",%/+%-<$+,-0-$<%5-"X;%/+<%./+%600$5%
/<7-.$%6+%4/X-+1%-4*567$4$+,"%,6%5$<#.$%$=*6"#5$2
Last line of defence
!+%,A-"%./"$%K$%K-88%.6+"-<$5%"/0$,R%-+",5#4$+,$<%
0#+.,-6+"%cF!^"d_%1$+$5/88R%,A$"$%/5$%/#,64/,-.;%8/",%8-+$%
60%<$0$+.$%"R",$4"%-+",/88$<%,6%4-,-1/,$%/%*/5,-.#8/5%
-<$+,-0-$<%A/m/5<2%D+%$=/4*8$%4-1A,%9$%/+%/#,64/,-.%
"A#,e600%7/87$%6+%,A$%0$$<%8-+$%,6%/%5$/.,65;%KA-.A%-"%
/.,-7/,$<%9R%/%A-1A%,$4*$5/,#5$%"$+"65;%/+<%<$"-1+$<%
,6%*5$7$+,%,A$%5$/.,65%67$5eA$/,-+1%/+<%#8,-4/,$8R%
0/-8-+1;%./#"-+1%/%86""%60%.6+,/-+4$+,%60%08/44/98$%
AR<56./596+"2%BA$%$+<%5$"#8,%60%,A-"%K6#8<%8-X$8R%9$%/%
7/*6#5%.86#<%$=*86"-6+%KA-.A%.6#8<%5$"#8,%-+%*56*$5,R%
</4/1$;%0-+/+.-/8%86"";%/+<%$7$+%0/,/8-,-$"%-+%,A$%86./8%
K65X065.$2%]$*$+<-+1%6+%/%+#49$5%60%0/.,65";%"#.A%
/"%,A$%*6,$+,-/8%"$7$5-,R%60%,A$%#8,-4/,$%-+.-<$+,;%-,"%
*6,$+,-/8%05$:#$+.R;%/+<%,A$%+/,#5$%/+<%5$8-/9-8-,R%60%
"64$%60%,A$%-+,$54$<-/,$%8/R$5"%60%*56,$.,-6+;%,A-"%F!^%
K-88%A/7$%/%5$:#-5$<%5$8-/9-8-,R;%65%"/0$,R%-+,$15-,R%8$7$8%
cF!Gd%KA-.A%-,%4#",%/.A-$7$%,6%9$%/98$%,6%*$50654%-,"%
<#,R2%
B6%1-7$%/+%-<$/%/"%,6%KA/,%"65,%60%5$8-/9-8-,R%8$7$8"%K$%
/5$%,/8X-+1%/96#,%A$5$;%46",%*56.$""%,5-*%0#+.,-6+"%
K6#8<%,R*-./88R%9$%$=*$.,$<%,6%*$50654%,6%/,%8$/",%
F!G%);%65%/%*569/9-8-,R%60%0/-8#5$%6+%<$4/+<%cL^]d%60%
9$,K$$+%)%-+%)(%/+<%)%-+%)((%,-4$"_%F!G%&%c#*%,6%/%L^]%
60%)%-+%)(((d%/5$%/8"6%:#-,$%.6446+%-+%,A$%$+$51R%
-+<#",5R;%9#,%/%6*$5/,65%K-,A%/%F!G%N%c#*%,6%)%-+%)(;(((d%
"R",$4%*569/98R%4/R%+6,%A/7$%,A6#1A,%$+6#1A%/96#,%
*567-<-+1%"#00-.-$+,%8/R$5"%60%*56,$.,-6+%65%6,A$5%
4-,-1/,-6+%4$/"#5$"%-+%,A$%67$5/88%<$"-1+2%F!G%.6","%'%
,A$%A-1A$5%,A$%5$:#-5$<%5$8-/9-8-,R%60%/%F!^;%,A$%465$%
,A$%6*$5/,65%A/"%,6%"*$+<%6+%A/5<K/5$;%,$",-+1%/+<%
4/-+,$+/+.$2
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Safety
Snippet

Advanced Process Control Instrument Identification

Do you use Advanced Process Control (APC)? How are maintenance
technicians made aware of which instruments in the field feed directly
into the APC system? Some facilities specially mark each field instrument
that feeds into the APC so that technicians are aware of the potential
impact of maintenance on that instrument.

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Introduction Check valve failures

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Main steam supply

isolation valve

HP Steam

Shaft HP Cylinder LP Cylinder

Generator

Extraction steam NRV Extraction steam NRV

LP steam header

Process steam header to plant

(HP steam header)

Additional steam feeds

to header

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!"#$%&'+$),","%'*04$1#1

The Energy Insurance Diploma The Energy Insurance and

Course – Beginners’ Level Risk Management Course –
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 The Energy Risk Management
Course – Advanced Level
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