Understanding Process Safety & Avoiding Catastrophic Failures - - PowerPoint PPT Presentation
Understanding Process Safety & Avoiding Catastrophic Failures LEARNING FROM 30 YEARS IN MAJOR HAZARD RISK CONTROL Ian Travers Process Safety Consultant www.iantravers.co.uk IAN TRAVERS LTD. PROCESS SAFETY CONSULTANCY WWW.IANTRAVERS.CO.UK
LEARNING FROM 30 YEARS IN MAJOR HAZARD RISK CONTROL
IAN TRAVERS LTD. PROCESS SAFETY CONSULTANCY WWW.IANTRAVERS.CO.UK
Ian Travers Process Safety Consultant www.iantravers.co.uk
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Why does it matter?
The most repeated responses from CEOs and Directors following a major accident. Safety is our number 1 priority – we always put safety first I just don’t understand how it could happen No one ever mentioned we had a problem We have professional safety experts We never skimp on safety We have extensive systems and procedures HSE has regulated us for years and we have never had anything serious wrong We have a comprehensive safety report scrutinised by HSE We have never had an incident before
IAN TRAVERS LTD. PROCESS SAFETY CONSULTANCY WWW.IANTRAVERS.CO.UK
IAN TRAVERS LTD. PROCESS SAFETY CONSULTANCY WWW.IANTRAVERS.CO.UK
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Flixborough
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Bhopal
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Pipa Alpha
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Bp Texas City
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Buncefield
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Toulouse Ammonium Nitrate
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Columbia shuttle
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Deepwater Horizon
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Esso Longford
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Seveso
Reliability and certainty that systems and procedures will work and deliver the safety,
environmental and business outcomes you need.
Asset failure modes understood and vulnerabilities identified and managed. Competent people delivering critical tasks to the required standard. Early warning of failures before disaster strikes. Effective leadership and positive culture promotes and supports critical outcomes.
What’s process safety management for?
IAN TRAVERS LTD. PROCESS SAFETY CONSULTANCY WWW.IANTRAVERS.CO.UK
Provides a way of managing risks which can not readily be seen Dealing with hazards and consequences which most people don’t have any direct experience of
Using the same approach to management of personal safety is not always sufficient for major
hazards
Need to different way of thinking and different approach to risk management
− A life-cycle approach
What’s process safety management for?
IAN TRAVERS LTD. PROCESS SAFETY CONSULTANCY WWW.IANTRAVERS.CO.UK
De- commission Concept Build Commission Start-up Operate Modify Shutdown Plant Life Cycle Maintain
Arrangements
Identification
Assessment
Parameters
Process Design Basis of Safety
Integrity / Management 9. Management
Procedures
Control
Work 8. Competence Management
Start-up Operation Shut-down
& Review
11. Management of Change
Process Safety Management System
Culture
What does a Process Safety Management System look like?
➢ Clearly setting out what hazards are present? ➢ What could go wrong? ➢ What systems and procedures we have in place to prevent serious incidents? ➢ How we ensure they are working all the time the hazard is present?
IAN TRAVERS LTD. PROCESS SAFETY CONSULTANCY WWW.IANTRAVERS.CO.UK
Maj Major A r Acc ccident Sce cenari arios
1. . Ship o
ffloading & & Product T Transfe fer t to Bulk T k Tanks 2. . Static S Storage ( (no product m move vement) 3. . Road T Tanker ker Filling 4. . Filling De Denaturant Tanks ks fr from R Road Tanker ker 5. . Ext xter ernal Even Events Ship-shore connection Pipelines to bulk tanks (including pumps, valves & flanges) Storage Tanks At tank Within bund from equipment At loading gantry Within tank bund(s) At road tanker gantry Pipeline to Tanks Storage tanks D1-12 Fire / Explosion on vessel in dock Fire / Explosion in premises adjacent to Methylation Facility Aircraft Impact Seismic event Lightning Storage Tank
Nicely:
lives
Unhelpfully:
IAN TRAVERS LTD. PROCESS SAFETY CONSULTANCY WWW.IANTRAVERS.CO.UK
Key stages of Safety Management – risk profiling
Risk Assessment Measures to control risks Hazard Identification Risk Profile
MAH 11 LoC Drum / pipeline
failure between drum & vacuum demand valve
Supplier error Drums not weighed on receipt
failure Failure of regulator
pipework Moisture ingress 4.Mechanical failure of vacuum regulator Cathodic protection failure Mechanical failure Failure to maintain correct temperature Impact / struck by object Poor maintence / purging 5.Cholorine degradation
Failure in inspection / maintenance Failure of quality control by supplier
Contamination / blockage Failure in inspection / maintenance
IAN TRAVERS LTD. PROCESS SAFETY CONSULTANCY WWW.IANTRAVERS.CO.UK
Bow Tie Model
Loss of Control
Outcome MAJOR HAZARD Preventive Barriers Mitigation Barriers
Procedure Safety Critical Task Procedure Maintence Active Control Sensor, Alarm & Shutdown
Demonstrating Control of Processes – detecting early signs of failure
Procedure Safety Critical Task Active Control Sensor, Alarm & Shutdown Procedure Maintence
Wrong method Late Not undertaken Step missed Wrong equipment Mistake Inaccurate Disconnected Mal function Understanding how controls fail & detecting when this happens before an incident
Risk / Reliability Acceptability
Arrangements
Identification
Assessment
Parameters
Process Design Basis of Safety
Integrity / Management 9. Management
Procedures
Control
Work 8. Competence Management
Start-up Operation Shut-down
& Review
11. Management of Change
Culture
Process Safety Management Framework
there was an associated loss of containment would this potentially lead to a major accident or a serious incident?
using the bow-tie analogy,
containment, and
partly or wholly on human intervention.
Safety Critical Vulnerable to failure
What you need to know and understand you can’t see. Sometimes the concepts of process safety seem like quantum physics: (you have heard about it, know its complicated but you couldn’t explain it to a someone else) Risk has been transformed into equations & numbers:
If you are uncertain about risk management you are probably reluctant to ask You probably want simple answers on complex issues
IAN TRAVERS LTD. PROCESS SAFETY CONSULTANCY WWW.IANTRAVERS.CO.UK
Every decision you make affects safety Do you understand how? Do you take process safety and risk management into consideration when making corporate decisions?
IAN TRAVERS LTD. PROCESS SAFETY CONSULTANCY WWW.IANTRAVERS.CO.UK
So leadership is vital – but what does it consist of?
The vision of the organisation. The way in which:
measures is communicated and championed.
Successful process safety management is essential for business success
Failure in process safety management can never deliver sustainable business success Your plant and equipment is both your benefactor and liability The consequences of getting control of major hazard wrong is extremely costly Getting it right pays large dividends
Management systems were both deficient and not properly followed, control room staff had little control over flow rates and timing of receipt and did not have sufficient information to manage precisely the storage of incoming fuel A culture where keeping the process operating was the primary focus and process safety did not get the attention, resources or priority that it required
IAN TRAVERS LTD. PROCESS SAFETY CONSULTANCY WWW.IANTRAVERS.CO.UK