This document discusses global best practices for safety and risk management. It outlines various stages of a project (planning, design, construction, commissioning, operations, decommissioning) and risk management tools that should be used at each stage, including hazard identification (HAZID, HAZOP), quantitative risk assessment (QRA), safety integrity level (SIL), escape/evacuation analysis (EERA), and behavior-based safety (BBS). The document emphasizes that a proactive, multilayered approach to risk management is needed to prevent major accidents.
This document discusses global best practices for safety and risk management. It outlines various stages of a project (planning, design, construction, commissioning, operations, decommissioning) and risk management tools that should be used at each stage, including hazard identification (HAZID, HAZOP), quantitative risk assessment (QRA), safety integrity level (SIL), escape/evacuation analysis (EERA), and behavior-based safety (BBS). The document emphasizes that a proactive, multilayered approach to risk management is needed to prevent major accidents.
This document discusses global best practices for safety and risk management. It outlines various stages of a project (planning, design, construction, commissioning, operations, decommissioning) and risk management tools that should be used at each stage, including hazard identification (HAZID, HAZOP), quantitative risk assessment (QRA), safety integrity level (SIL), escape/evacuation analysis (EERA), and behavior-based safety (BBS). The document emphasizes that a proactive, multilayered approach to risk management is needed to prevent major accidents.
This document discusses global best practices for safety and risk management. It outlines various stages of a project (planning, design, construction, commissioning, operations, decommissioning) and risk management tools that should be used at each stage, including hazard identification (HAZID, HAZOP), quantitative risk assessment (QRA), safety integrity level (SIL), escape/evacuation analysis (EERA), and behavior-based safety (BBS). The document emphasizes that a proactive, multilayered approach to risk management is needed to prevent major accidents.
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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
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
