Tata Steel Slide “Centre of Excellence: Tata Steel way to Process Safety” Moving the Culture from Compliance to Risk Management 8 th August,2019 CII, 13 th Safety Symposium & Exposition
Process Safety Management Tata Steel Slide 1 Contents 1. What is Process Safety 2. CoE concept of Process Safety Management (PSM) Deployment 3. Deliverables of PSM Deployment 4. Sustenance Activities
Process Safety Management Tata Steel Slide 2 Contents 1. What is Process Safety 2. CoE concept of Process Safety Management (PSM) Deployment 3. Deliverables of PSM Deployment 4. Sustenance Activities
Process Safety Management Tata Steel Slide 3 3 What is Process Safety? “Process safety is a blend of engineering (Design & Maintenance) , operations and management skills focused on preventing catastrophic accidents , particularly structural collapse, explosions, fires and toxic releases associated with loss of containment of energy or dangerous substances such as toxic gases, molten metal, chemicals and petroleum products. These engineering (Design & Maintenance), operations and management skills exceed those required for managing workplace safety.”
Process Safety Management Tata Steel Slide 4 4 How Process Safety is different from Occupational Safety 4 Logic to Implement Process Safety Management High Implement Process Safety No Future In a steel plant here ! Consequence Example – Liquid Metals/ Toxic gases there is a need to implement both Occupational safety & “The Goal is Implement Process safety Zero Harm” Occupational Safety Example – Slip / Trip/ Fall Low Low Frequency High
Process Safety Management Tata Steel Slide 5 Process Disasters at Indian Steel Industry Process Safety Incidents can: SAIL-Bhilai- Gas leakage GCP (6 †) Vizag Steel- O2 PRS explosion (18†) • Kill and injure many people ; • Cause massive and long lasting pollution; • Cause major economic disruption ; CO Gas Line Fire Bhilai Steel (14+) Bhusan Steel- Dry pit explosion • Severely damage a company’s (6†) reputation ; • Cause companies to become “paralyzed” in the aftermath; • Lead to companies and individuals being prosecuted .
Process Safety Management Tata Steel Slide 6 Tata Steel LD Gas Holder Explosion : Failures of PSM Elements The incident investigation revealed failures at multiple levels Oxygen 1 Fuel LD GH explosion Tata Steel (1 †) Pushing atmospheric air into the 2 LD Gas Holder (PLC Failure) LD Gas - Inherent hazard - Inadequate Preventive present barriers - Barriers not maintained Ignition Source Ignition 3 Spark from Electrostatic Precipitator - Risk was not understood PSM- Process Safety Management PLC- Programmable Logic Control
Process Safety Management Tata Steel Slide 7 Contents 1. What is Process Safety 2. CoE concept of Process Safety Management (PSM) Deployment 3. Deliverables of PSM Deployment 4. Sustenance Activities
Apex PS & DM Subcommittee Tata Steel Slide 8 Tata Steel benchmarked its PSM System with best in class Asset Management is Leadership & a weak area across the Accountability 5 organisation 4.5 Audit & Review Competent People 4 3.5 - Barrier management 3 can improve this 2.5 2 Measuring Performance Hazard Identification 1.5 Hazard Identification is 1 0.5 another weak area for 0 Tata Steel Emergency Preparedness Risk Management Audit & Review system needs improvement Operational Control Asset Management Management of Change Tata Steel Jamshedpur 2014 Tata Steel Europe 2007 Centre of Excellence Oil & Gas Co. (CoE) for Process Safety Pharma Co.
Process Safety Management Tata Steel Slide 9 Centre of Excellence (CoE) Approach for PSM : Key Objectives Capability & Competency Building ▪ Capability enhancement of operators following 70:20:10 approach on PSRM System & Documentation ▪ To review and upgrade existing procedures and tools for PSI, PHA, MoC and PSSR. ▪ To strengthen current PSI & PHA documents as per revised procedure Field Implantation ▪ Strengthen the Inspection & Maintenance system of PSM critical equipment ▪ Upgrade the OP to manage Process Critical Parameters 2. System 1. Capability & & ▪ Competency Implementation of Recommendations to reduce the Risk leve Building Documentation 3. Field Implementation
Process Safety Management Tata Steel Slide 10 Capability and Competency Building Exemplar Practitioner 3- IBF Beginner 48 at IBF 3-LD#1 All employeesat 48 at LD#1 2 -SHE in both facilities 20 10 70 Handholding , Class Room On the job learning by Coaching by Experts Training assigning task & guidance • Kaizen, SGA , SIP/ Suggestion Safety Visit and Observation • Developing PSI and • Daily Interruption PHA by TPM team • Shutdown / Breakdown PSM observation in Field Visit • PSI/PHA /MoC Training • Revised MoC Procedure • PSM Field Visit Checklist Card Shop floor Poster Campaign • 100% Shop floor Training
Process Safety Management Tata Steel Slide 11 Felt Leadership : PSM Line Walk ➢ Developed checklist & conducting PSM line walk ➢ Involving cross functional leaders & Poor critical equipments TPM/SGA team upkeep ➢ Weekly PSM Line Walk & review by Corrosion Improper support chiefs IBF &LD1 ➢ Horizontal deployment across JSR works by Apex PS&DM SC Item Check Points 1. Understanding of Hazards of respective area, Emergency Conditions & Response. 2. Awareness on top 5 scenarios PSM 3. Implementation of PHA recommendations at Shop Floor Awareness 4. Pay attention to the new employees and contractors for the Structural Poor condition understanding of safety knowledge (communicated with 3 Cable conduit integrity employees at least) vibration pad damage 1. Condition of foundations 2. Anchoring of structures Structural 3. Corrosion/Cracks of foundation Integrity 4. Temporary structures if any 5. Bending/Sagging 6. Critical equipments physical condition (Select from P&ID) 1. Condition of pressure vessels (Physical Condition of pressure Non-uniform play vessel, Test date, Relief System tests etc.) given for 2. Heat exchangers(Corrosion or mechanical damage, wear, or Process fouling, c ondition of gasket surfaces) compensators Color coding of Leakage from large Containmen 3. Rotating equipment (Abnormal sounds, fouling structures above it) pipelines t tanks 4. Critical Piping System/Storage Tanks 5. Torpedo/ladle/Gas networks system 6. Colour codlings
Process Safety Management Tata Steel Slide 12 PSM Deployment Framework 12 Steps 1- 5 1. Identify High Hazard Facilities Step 6 2. Categorize the processes as High Hazard & Low Hazard operations 1.Model the consequence 3. Develop the process safety (Multiple Fatality) potential information (PSI) scenario 4.Identify the hazards, evaluate the Management of Change Management of Change consequence and risk ranking (Process Hazard Analysis) Fire, explosion, Barrier Management – Application to potential major accident Barrier Management – Application to potential major accident hazard toxic/energy release, 5.Project Hazard Study hazard events (Fatality & Multiple Fatality Consequence ) events (Risk Grid consequence >3 ) environmental damage Steps 7 & 8 7.Identify number and type of Barriers - Safety critical Process Safety Critical equipment and tasks Equipment (LTI & above consequence) 8.Assess Barrier health Safety Critical Tasks Step 9 1.ALARP* demonstration through Layer of Protection Analysis Step 10 (LOPA) 1.Human factor analysis ALARP Demonstration Operational Control Asset Management Procedures, Training & Design, Maintenance & Quality Assurance Competence of Employees and Contractors Risk Reduction, Emergency Preparedness & Control Monitor, Audit, Incident Investigation & Review PSM CoE- Process Safety Management Centre of Excellence ALARP- As Low As Reasonably Practicable LTI – Lost Time Injury
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