Kuwait National Petroleum Company Safety Management Systems journey - - PowerPoint PPT Presentation

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Kuwait National Petroleum Company Safety Management Systems journey - - PowerPoint PPT Presentation

Oct 25, 2023 367 likes •661 views

Kuwait National Petroleum Company Safety Management Systems journey KNPC HSE Department 2010 1 Kuwait National Petroleum Company Kuwait National Petroleum Company (KNPC) processes 736 MBPSD at its two refineries Clean Fuels Project

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KNPC HSE Department 2010

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Kuwait National Petroleum Company – Safety Management Systems journey

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Kuwait National Petroleum Company

  • Kuwait National Petroleum Company (KNPC) processes

736 MBPSD at its two refineries

  • Clean Fuels Project expansion will improve the quality of

product substantially- expected completion date- Apr 2019

  • KNPC formed initially as a private local distribution ;

Government take over in 1976

  • KNPC has around 6000 employees and several thousand

contractor personnel

  • KNPC is run professionally under the ownership of Kuwait

Petroleum Corporation (KPC)

  • KNPC enjoys leadership position among downstream

sector in Middle East in Technology and Health, Safety & Environment

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KNPC HSE Department 2010

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Organization

CEO

Deputy CEO- Support services

Manager, Health Safety &

Environment

Manager, Security & Fire

TL, Safety- MAA TL, Safety- LM & HO TL, Safety- Projects TL, Technical Support-HSE TL, Medical TL, Environment TL, Safety- MAB TL, PSM

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KNPC Mission, Vision and Values

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KNPC QHSSE Policy

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KNPC Management System/ SMS/ PSM journey

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  • 12. Behavioral Accident Prevention

Phase-3

  • 13. Training

Phase-3

  • 14. Mechanical & Operating Integrity

Phase-3

June 2001

  • 6. Roles & Responsibilities

Phase-2

  • 7. Occupational Health

Phase-2

  • 8. Employee Ownership & Participation

Phase-2

  • 9. Standards & Procedures

Phase-2

  • 10. Audits

Phase-2

  • 11. Emergency Preparedness

Phase-2

March 2000

The First Safety Management System 1996-97

Dec 1997

  • 1. Leadership & Commitment

Phase-1

  • 2. Metrics

Phase-1

  • 3. Contractors

Phase-1

  • 4. Incident Reporting & Investigation

Phase-1

  • 5. S&OH Planning

Phase-1

Jun 1998 May 1998 Dec 1998

Original Schedule Revised Schedule

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Incidents that changed the course

  • Shuaiba refinery

confined space tragedy, 15 June 2000

  • Mina Al Ahmadi

refinery fire and explosion, 25 June 2000

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SHEMS Elements, 2001

Sr.# SHEMS Elements 1. Leadership, Commitment & Accountability 2. Management System, Metrics and Audits 3. Safe Work Practices, Permits and Standards 4. Training and Competence 5. Environment 6. Information and Documents 7. Contractor & Material Procurement 8. Roles, Responsibilities and Assignments 9. Behavior 10. Occupational Health 11. Emergency Preparedness 12. Incident Investigation and Reporting 13. Risk Assessment and Management of Change 14. Mechanical and Operating Integrity

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KPC HSE initiatives

  • HSE Department formed
  • HSE Management System initiated with Du Pont,

for implementation by all subsidiaries

  • Incorporated Process Safety Management

requirements

  • Corporate PSM Committee formed (2007) to
  • Support implementation
  • Raise awareness
  • Upgrade documents
  • Monitor implementation
  • Review performance
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KPC PSM elements

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KNPC PSM Implementation Program 2008

  • Resolved to implement KPC PSM requirements
  • Process Safety Culture Survey to identify issues &

concerns

  • PSM Implementation Committee formed
  • Element wise subcommittees formed
  • Three year implementation plan 2010-2012
  • New processes introduced
  • New organization (PSM Team) in place
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KNPC i-SHEMS elements

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KNPC PSM Programs & Initiatives

  • MOC Audits
  • PSSR process introduced, good response on CFP

commissioning

  • PSM KPIs introduced per API 754, being monitored
  • Incident investigation process upgraded
  • PHA revalidation began
  • Contractor HSE performance database
  • ESD interlock bypass process automation
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  • First company in the region fully implemented API -754 PSM KPI

which was well appreciated by international insurance survey .

  • PSM KPI dashboard e-Portal developed and implemented.

KNPC PSM Measures

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0.072 0.072 0.056 0.06 0.097 0.078 0.02 0.04 0.02 0.04 0.06 0.08 0.1 0.12 Year 2014-15 Year 2015-16 Year 2016-17 Year 2017-18

KNPC Tier-1 PSER

Concawe Tier-1 Actual Tier-1

KNPC PSM Measures

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KNPC PSM Measures

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Mechanical Integrity - Safety Critical equipment

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Mechanical Integrity--Safety Critical Equipment program: Identified and verified; almost 40,000 equipment were categorized, risk ranked and well maintained as SCE through inspection, maintenance and spare parts program

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Safety Culture Improvement Program

A Safety culture improvement program which includes Safety Culture survey is being carried out to review the effectiveness of the safety culture programs (for employees and contractors) and develop a corrective action plan to enhance safety culture. This is a 3 year project.

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KNPC Integrated Management System for ISO requirements (IMS), 2017

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Integrated Management System

1. KNPC had been certified to ISO 9001, Quality Management System, ISO 14001, Environment Management System and OHSAS 18001, OHS Management System 2. In May 2017, Integrated Management System project unified their implementation

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IMS Implementation Timeline

  • 4. Work Scope for Consultant/Certifier
  • 3. Revision of IMS Committee
  • 1. Gap Analysis to revised standards:
  • 5. Preparation & Award of contract
  • 7. System Document Revision
  • 2. Presentation on revised Standards

(ISO-9001, ISO-1400 & ISO-45001)

  • 6. Re-nomination of IMS Coordinators
  • 11. 1st Internal Audit
  • 10. Revision of Dept./ Div. OHS Risk,

Aspect & Business Risk Registers

  • 8. Awareness & Communication

4 8 12 20 16 28 24 36 32 44 40 48 52 56 60

WEEK

  • 12. 1st Certification Audit
  • 13. Award of Certificate

31.01.2016 31.01.2016 31.01.2016 30.06.2016 Continuous 30.03.2017 31.03.2016

  • 9. Training of Management, Auditors, &

Coordinators

30.12.2016 14.11.2016

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Completed Completed 17.05.2017 06.04.2017 20.04.2017 20.02.2017

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1. Short time – large company 2. Major management of change issue 3. Upgraded to 2015 editions of ISO 9001 and ISO 14001 4. Among the first in major companies in GCC

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  • Fig.4 major achievement

IMS Implementation – challenges and accomplishments

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Safety awards achieved by KNPC

Awards from Royal Society for the Prevention of Accidents (RoSPA)- U.K.: KNPC sites regularly achieve Achievement awards from RoSPA Awards from British Safety Council (BSC) U.K. KNPC sites regularly achieve International Safety Award from BSC

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Safety awards achieved by KNPC

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Future

  • Improvements in management systems have led to

improvement in performance

  • KNPC aspires to be abreast with the best
  • Likely to upgrade to ISO45001 from current BS

OHSAS 18001 by mid 2018

  • Future integration planned with IT Security ISO

27001, Food Safety ISO 22001 and Energy Standards ISO 50001

  • Further improve compliance and auditor development

program

  • Further enhancement of PSM performance
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