Process Safety Management

Integrating Process Safety into the Santos EHS Management System

2008 National Conference on Major Hazard Facilities March 2008 Andrew Antony Manager EHS & Sustainability

Process Safety Management

Over the past 5 years Santos has been establishing a process safety management system.

4 key stages Establishing the right platform Defining new standards Integrating process safety Auditing and monitoring performance

within a framework that manages environment, health and safety in a consistent manner across the company
2.

Santos Process Safety Journey

Process safety capability has been improving over time

2002-2004

2005

2006

2007

2008

Moomba Integrity Review Whole of Plant Risk Assessments

Procedures Upgrade

Operations Excellence Benchmarking Forum Established

Appointment PSM leader & Principal Engineer

Process Hazard Analysis Audit program Training PSM standards Appointment Lloyds Register

Asset Integrity Management System

which was formalised through a revision to EHSMS

3.

A simple definition.
PSM is used to manage major incident risks

The application of management systems for the identification, understanding, and control of process hazards to prevent process related injuries and incidents.
(CCPS)

4.

Process Safety Management

4 key stages Establishing the right platform Defining new standards Integrating process safety Auditing and monitoring performance

5.

Environment, Health & Safety

Santos has an integrated approach to manage EHS
Safety Health Environment Cultural Heritage Greenhouse Sustainability Security
Procedures Tools, guides & practices Policy Management Standards EHS Hazard standards

EHSMS assessment program

Site Procedures

.which provides guidance to all employees & contractors

6.

Safety Systems
Implementation of the EHS management system..
Annual improvement across all sites core systems in place Most sites now within the continuous improvement zone Moving to audits of effectiveness Key focus areas contractor and risk management
(%)

EHSMS Management Standard Assessments

100 80 60 40 20 0
t t E l w ia USA s eter n r t ee n d enie la n tra D&P lan es se po an tho rvie en up a Bal ny era P ba P eesl M ere ces er Ex F ai Indon C S o o r i l n s P om ne Qu rt B Bal Op Patric ctio on Muti Po M o te r n du S& s mm H o Pro Ea E Baseline in 2006 C
2003 2004 2005 2006 2007

Continuous Improvement Zone

has delivered consistent, effective safety approaches across all sites and operations
7.

Personnel Safety
Downward trend in injury rates..
Key Programs Safety leadership & expectations Back to basics skills Hand & finger injury program Hazard awareness skills Health & Wellbeing Drug & Alcohol testing Contractor management Driving safety
8.

Total Recordable Case Frequency Rate

20 16 12 8 4 0 98 99 00 01 02 03 04 05 06 07
Santos

Personnel safety
Personnel Personnel Safety Safety low low consequence, consequence, high high frequency frequency

Fatalities

Recordable Cases First aid cases Near Misses Personnel Safety Hazards & Behaviours

9.

Safety Personnel & Process

Personnel Personnel Safety Safety low consequence, low consequence, high high frequency frequency
Fatalities

Process Process Safety Safety high consequence, high consequence, low low frequency frequency

Recordable High Impact Cases Incidents First aid cases Loss of containment Process Safety Exceptions

Process safety Centres around loss of containment of hydrocarbons Has a potential order of magnitude higher consequence than personnel safety incidents

Near Misses

Personnel Safety Hazards & Behaviours

Process Safety Hazards & Behaviours

The focus of process safety is to establish systems, standards and behaviours that will prevent catastrophic events
10.

Process Safety Management

4 key stages Establishing the right platform Defining new standards Integrating process safety Auditing and monitoring performance

11.

New Standards
Process safety has formalised existing practices and established new standards.
Design & construction Hazard analysis Integrity Maintenance Protection Systems Procedures & practices Fire risk management
Procedures Tools, guides & practices

EHSMS
Policy Management Standards EHS Hazard standards

Assessment/ Audit

..to reduce the risk of loss of containment from plant integrity or system failure resulting in serious injuries or plant damage
12.

Layers of protection concept

SAFE OPERATION

Management System
Process Hazard Analysis Management of Change

Design Basis Design & Construction Pre Start-up Review

Operating Procedures & Safety Practices Maintenance Integrity Management Ignition Control Critical Protection Systems

Training and Competency Risk Assessments MAJOR INCIDENT

13.

New Standards
14 new standards..
Operations Integrity Design Basis Facility and Equipment Facilities Design and Construction Pre Start-up EHS Review Structural Integrity Mechanical Integrity Ignition Control Critical Protection Systems Operating Procedures and Safe Practices Maintenance Fire Risk Management Decommissioning and Abandonment Management of Personnel Change
14.

Process Safety Management

4 key stages Establishing the right platform Defining new standards Integrating process safety Auditing and monitoring performance

15.

Integration
Santos Environment Health and Safety Management System

Amended Standards
Common EHSMS Standards

Process Safety Standards

Health and Safety Standards

Environment Standards

New Standards

16.

Integration
17 amended standards.
Legal & Other Obligations EHS Objectives, Targets & Improvement Plans Responsibility & Accountability Training & Competency Consultation and Communication Document & Records Management Hazard Identification, Risk Assessment and Control + Hazard Studies Contractor and Supplier Management Operated by Others Management of Change (MOC) Acquisition and Divestment of Assets Emergency Preparedness Monitoring, Management & Reporting Incident Investigation Management System Audit and Assessment Management Review
17.

Santos Process Safety Journey

Process safety capability has been improving over time
EHSMS Revision

2002-2004

2005

2006

2007

2008

Moomba Integrity Review Whole of Plant Risk Assessments

Procedures Upgrade

Operations Excellence Benchmarking Forum Established

Appointment PSM leader & Principal Engineer

Process Hazard Analysis Audit program Training PSM standards Appointment Lloyds Register

Asset Integrity Management System

which will be formalised through a revision to EHSMS

18.

Process Safety Management

4 key stages Establishing the right platform Defining new standards Integrating process safety Auditing & Monitoring performance

19.

Auditing
Santos is currently changing from assessments to audits.
EHSMS
Policy Management Standards EHS Hazard standards

Assessment/ Audit

Detailed audit protocols Audits typically 2-3 weeks Audit teams typically 5-6 people covering

Procedures Tools, guides & practices

- Process safety - Personnel safety & health - Environment

Moved away from scoring Now identify strengths and non conformances

..which cover all EHS areas including process safety

20.

Reporting Process Safety Events

DESCRIPTORS Loss of containment from plant integrity or system failure resulting in a fatality Loss of containment from plant integrity or system failure resulting in multiple injuries, hospitalisation or significant plant damage Loss of containment with potential to cause multiple injuries, hospitalisation or significant plant damage Significant process safety breach, involving loss of a layer of protection, including loss of mechanical integrity, failure of shutdown system or critical operating limit exceedence Minor process safety breach, including exceedence of safe operating envelope for temperature, pressure, corrosion or process chemistry, or a critical operating parameter alarm

Fatality High Impact Incident

Loss of Containment

Process Safety Exception

Process Safety Hazards & Behaviours

21.

Reporting Process Safety Events

Fatality

High Impact Incident

1. Large release Any crack, release pinhole, etc, in 2.1.Widespread process piping, leaking or not 3. Release requiring site 2. Ignition sources created (eg, evacuation

Loss of Containment

Process Safety Exception

Process Safety Hazards & Behaviours

fire, electrical, pyrophric, 1. Permit to work (PTW) breach smoke, etc) 2. Incorrect tagging 3.Inadequate Non-compliance applicable 3. blindsto list standards (Santos, Australian, 4. Inadequate critical drawing International) 5. Undesirable and frequent PSV 4.operation Permit to work (PTW) breach 5.Inaccurate Permit to work (PTW) failure of 6. or delayed response 6.aUnexpected extreme corrosion primary response system 7.Changes Valve left open (open port) 7. without management of 8.change Changes without management (MOC) of change (MOC) to standards 8. Non-conformance
9. Automatic detection/ protection system de-activated

22.

Root Case Analysis Trending

Santos trends process safety events using the following list of controls which appear common across most industry.
Hazard & Risk Analysis Plant Commissioning Permit to Work Fire Protection Management of Change Operating Procedures Training & Competency Plant Design Inspection & Testing Maintenance Outcomes

23.

Monthly Reports
Monthly charts have triggered improved reporting.
Process Safety Loss of Containment Incidents by Category 2007
5

Process Safety Exceptions by Category - 2007 YTD

4% 5% 2%1%

Hazard & Risk Analysis Commissioning

Maintenance Outcomes
22%

Inspection & Testing

9%

Permit to Work
3

Plant Design Training/Competency Operating Procedures

Fire Protection Management of Change

Operating Procedures Training/Competency

12% 14%

Management of Change Fire Protection Permit to Work

11% 20%

Plant Design Inspection & Testing

Commissioning Hazard & Risk Analysis

0 Jan Feb March April May

Maintenance Outcomes

Process Safety Exceptions by Category by Month 2007

25

Process Safety Exceptions by Site 30 25 20 15 10 5 0

Hazard & Risk Analysis Commissioning

20

Permit to Work Fire Protection

15

Management of Change Operating Procedures

10

rr a

ga

lle Ba SW Q Fi

om

om

l lin

wa

Mo

Mo

Du

r ra

0 Jan Feb March April May

Maintenance Outcomes

24.

Ti

e ld

Inspection & Testing

Pr

od

ba

ba

Plant Design

t uc t M e io n re en ie Fa i rv Ly ie t to W w n al T l um er m bi in ll a al & S Po SW rt B o .. ny Mu th t in on ee rE xe ter Oy on g

e ld

e ld

e ld Fi

an

Pl

Fi

Fi

ra

ri

Pl

an

Training/Competency

Benefits
Process Safety is vital part of the on-going management of Santos facilities and operations Process Safety is now integrated into the EHSMS For Santos this will mean

- Specific management of process safety risks - Establishment of new performance indicators to

monitor the ongoing management of PSM risks responsibilities for staff

- Improve definition of specific process safety

This will result in

- Reduced process safety exceptions - Reduced loss of containment - Improved management of process safety issues
25.