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.

Wide spectrum of
Industrial Sectors..
Pharmaceuticals
Petrochemicals
Oil & Gas
Refinery
Agrochemicals
Specialty Chemicals
Textiles
Fertilizers
Paint & Coatings
Engineering
Building (Hotels,
Hospitals, Corporate)

Our Clients

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 Procedures

Engineering

Mitigation

Alarms & Procedures

Emergency Response

Passive Devices

Prevention of Escalation
to other vessel

Prevention of Escalation
from other incident

Layers of Protection Analysis (LOPA)

COMMUNITY EMERGENCY
RESPONSE
Emergency Scenario
Training
Fire Protection
PSVs
SIS
RBI
Process
Alarms
Operations
Supervision

Operating vs Design Verification

PLANT EMERGENCY
RESPONSE
MITIGATION
SYSTEM
PREVENTION SYSTEM
BPCS
PROCESS DESIGN
PROCESS

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
hazards as the first stages of demonstration of ALARP.

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:
- Process hazard checklist
- Hazard survey: DOW index
- HAZOP hazard & operability study
- Safety review
RISK ASSESSMENT:
- What can go wrong & how ?
- What are the chances ?
- Consequences ?
EXTREMES
- Low probability
- Minimal consequences

System description
Hazard identification
Scenario identification

Accident

Accident

probability

consequences

Risk determination

risk &
hazard
acceptable
? Y
Accept system

Modify design

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 subcomponents are vulnerable to fire and explosion events;
To determine whether emergency system subcomponents 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
Prevention of accidents should be the goal:
Design options (use of chemicals, technology etc)
Layout review (various locations and configurations)
Project HSE Review (PHSER)
Hazard Identification (HAZID)
Risk Register

Design Stage
Adequate Design suitable for operations:
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
supply & maintenance
of plant, hardware,
software, control
systems etc, along
with their design and
layout to eliminate,
control or mitigate
risks and improve
productivity
throughout the asset
lifecycle

processes
management systems,
processes, procedures
and other work
systems to identify,
control and mitigate
risks and to improve
operational
performance

people
organisation, roles &
responsibilities,
knowledge, training,
experience, resource
levels and capability
along with the
mindsets & behaviours
of personnel

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
CHILWORTH TECHNOLOGY P. LTD.
Muskaan Complex, B-2, Plot No. 3,
Vasant Kunj, New Delhi - 110070
Tel: + 91 11 26136979; Fax +91 11 26135979
www.chilworth.co.in