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?

Dont wait for a major accident to identify need to

improve major hazard management.

Need to learn lessons from accidents (Hindsight)

but dont 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 BPs largest plant,

and the USAs 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
Engineering Procedures
Alarms & Procedures Mitigation
Passive Devices Emergency Response
Prevention of Prevention of
Escalation from other Escalation to other
incident vessel
 Layers of Protection Analysis (LOPA)

COMMUNITY EMERGENCY
RESPONSE

Emergency Scenario PLANT EMERGENCY

Training RESPONSE
MITIGATION
Fire Protection SYSTEM

PSVs 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
 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
Scenario
study identification
- Safety
RISK review
ASSESSMENT: Accident Accident
- What can go wrong & probabili consequenc
ty es
how ?
Risk determination
- What are the chances ?
- 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, companys 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 & management organisation, roles
maintenance of systems, & responsibilities,
plant, hardware, processes, knowledge,
software, control procedures and training,
systems etc, along other work systems experience,
with their design to identify, control resource levels and
and layout to and mitigate risks capability along
eliminate, control and to improve with the mindsets
or mitigate risks operational & behaviours of
and improve performance personnel
productivity
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@chilworth.co.in

CHILWORTH TECHNOLOGY P. LTD.

Muskaan Complex, B-2, Plot No. 3,
Vasant Kunj, New Delhi - 110070
Tel: + 91 11 26136979; Fax +91 11
26135979
www.chilworth.co.in