Global Best Practices in Safety Contents

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.

Wide spectrum of Industrial Sectors…. . § Pharmaceuticals § Petrochemicals § Oil & Gas § Refinery § Agrochemicals § Specialty Chemicals § Textiles § Fertilizers § Paint & Coatings § Engineering § Building (Hotels, Hospitals, Corporate) Our Clients

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 – 11 December 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 other vessel” – Prevention of “Escalation from other incident”

Layers of Protection Analysis (LOPA) COMMUNITY EMERGENCY RESPONSE Emergency Scenario Training Fire Protection PSV’s SIS RBI Process Alarms Operations Supervision Operating vs Design Verification PLANT EMERGENCY RESPONSE MITIGATION SYSTEM PREVENTION SYSTEM BPCS PROCESS DESIGN PROCESS

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: - Process hazard checklist - Hazard survey: DOW index - HAZOP hazard & operability study System description Hazard identification Scenario identification - Safety review RISK ASSESSMENT: - What can go wrong & how ? - What are the chances ? - Consequences ? EXTREMES - Low probability - Minimal consequences Accident probability consequences Risk determination risk & hazard acceptable ? Y Accept system N Modify design

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 subcomponents are vulnerable to fire and explosion events; • To determine whether emergency system subcomponents 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 – supply & maintenance of plant, hardware, software, control systems etc, along with their design and layout to eliminate, control or mitigate risks and improve productivity throughout the asset lifecycle processes – management systems, processes, procedures and other work systems to identify, control and mitigate risks and to improve operational performance people – organisation, roles & responsibilities, knowledge, training, experience, resource levels and capability along with the mindsets & behaviours of personnel 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