Offshore Group Webinar Process Safety Insights

foreign good afternoon everybody my name's Simon hatz and I'm the current chair of the offshore group and I have the pleasure of hosting today um just to just a few things before before I hand over to sholesh our speaker for the day um for those of you who are already members of the group you will know that this is the third webinar that the offshore group have been involved in and I thank you all for for attending um this is actually the first joint event that we've done with the Hazardous Industry Group and I think that the Hazardous Industry Group for doing this with us and they've been a fantastic support throughout and shirlesh your speaker is a member of that committee and so I thank you in advance for what he's about to speak about um hopefully all being well this will be the first in a series of webinars that between the two between the two groups we will look to put on for you but obviously that will be dependent upon the feedback we get from yourselves so as Ben rightly said throughout the session if you do have questions if you do have comments please do take the time to raise them and and also following the event you will get the opportunity to raise some feedback and to generate some feedback coming out the event and what I would say to you is that that will be read and analyzed both by both ourselves and the Hazardous Industry Group so please do take the time to feedback to us your opinion genuinely does matter and it will genuinely determine what we look to do moving forward so if you could take the time to do that when the opportunity arises would be very grateful as Ben said um please raise your questions throughout the event and what we will do we'll do the question and answers at the end I'll I'll pose the questions to chalesh and obviously and hopefully try and get the answers that you were looking for my final thing to say and I'm really Keen not to take it too much time away from shalesh is just to say this everybody who's who's dialed in today you've all done so for a reason I don't know what that reason is but I'd imagine there's something within the content that you are hoping to learn whether it's a question you've always want answered or something you wanted a bit more insight into so you do have the ability to raise questions so please if there is a question that that you have that hasn't been answered especially towards the end of the presentation please do take the time to raise it because I would hate for any of you who have taken the time to dial in to leave the today's session without the answers you were looking for so without further Ado I will hand over to chalesh who will take you through his presentation good morning good afternoon and good evening my listeners first of all may I please thank you for your time and the interest you've shown in this presentation uh as for the title it is about awareness it's not the full monty as they say for process safety but it's a beginner's guide and in this one I'll be using various standards now the first picture I have is is a small clip some of you may have seen it apologies to those who have seen it before but this gives you a clue as to what we'll be talking about later on there's no sound on it so please don't turn a volume on your uh on your screen please there she comes again Hallelujah so this is going back so the question I'm asking is what do you think led to this incident now I don't expect an answer straight away but it's to do with electrostatic charge and in process safety this is a source of ignition moving on now my objectives for this session is to Define what process safety is explain the difference between occupational safety and process safety describe the 10 pillars of compliance approach which I'm going to follow there are various standards as people who may be aware there's the OSHA process Safety Management standard there is also a very good energy Institute guidance on process safety framework but for the purpose of this session to keep it simple and very much targeted I'm going to use the 10 pillars of compliance approach which is applicable to any process Safety Management System it's a very basic and simple process and this is the approach which the UK Regulators health and safety executive have followed so when they come on one of the sites which are grown by control of major accident Hazard regulations they follow this approach so I'm sticking to that one makes life easy for us I'm going to outline consequences of process safety failures with a few examples and I'm going to highlight the key part played by human factors in achieving high pressure safety standards so thankfully human interaction is very good and it's very essential in achieving process safety most of the stuff that I'm going to talk about will not come as a surprise to you you've already do that as just explaining the link what is process safety social safety generally refers to prevention of unintentional releases of chemicals energy or other potentially dangerous materials during course of a chemical process that can have a serious effect on the plant in the environment process safety for example involves for prevention of leaks spills equipment malfunction over pressures over temperature corrosion metal fatigue and other similar conditions process safety programs actually focus on design and Engineering facilities maintenance of equipment effective alarms effective control points procedures and training in other words everything we do on the actual Hardware on the equipment that we have it's sometimes useful to consider process safety as an outcome or result of a wide variety of technical management and operational disciplines they all come together in organized way to give us a safe outcome the figure next to it gives you like a very broad view of what's involved and the Heart of this processity will as I like to call it is management leadership and just to stress that point let's talk about the differences between personal safety which I would say is occupational safety and process safety so if we look at the typical safety triangle hopefully you would have seen this so there's Health environment and safety the same triangle on both sides but in occupational safety or personal safety we tend to construct more on preventing harm to people on people's health and to people's safety for example we wouldn't be running dangerous machines with chop off people's fingers without inadequate with inadequate guarding Etc but in process safety we consider it more on preventing losses or long-term harm to the environment and also the safety so we're talking about fires and explosions here okay how how do we do this what are the little indicators of danger that's my favorite saying what are little indicators of danger in personal safety and process safety so if we look at the figure the triangle there so examples of getting personal safety wrong are injuries manual handling exposure and in process safety the examples could be fire explosion pollution Etc if you look at the typical triangle the focus on personal safety is picking it up very early on so you get lots of near misses you get lots of minor incidents and if you don't some do something about it you could get serious incident and haven't forbid a fatality but in process safety is the other way around the unless you are very much focused on process safety and do your process safety uh performance monitoring rigidly and rigorously then until something goes wrong such as a serious accident or a fatality you have no clue that things are not running right so it's very important and this is one of the pillars of process safety which I'll explain later on moving on to control the hazard for personal safety we actually we should focus on elimination and substitution but usually it's very easier to say here wear this hard at and you'll prevent injuries to your head where this safety goggles to your eyes will not be taken out by a corrosive chemical so these are administrative and PP and people often go for these controls and they they are in the hands of the front line workers operators and supervisors but whereas in process safety notice responsibility to Hazard control is hands of Senior Management and Engineers so elimination and Engineering are the first preferred choices PPE will not stop a process safety incident and that's an important difference but to be quite Frank there's no dividing line between the two types and we must get both of them right overall objective is in an industrial setting in a work setting you don't want to harm the people you don't want to burn down the Plant and you don't want to cause Finance lotions or severe environmental pollution I hope that is pretty obvious for all of us so here are my wonderful 10 pillars of compliance so this is a list of 10 pillars of compliance which is followed by the competent Authority within the United Kingdom so it consists that the competent authority comprises of the health and safety executive who look after safety and health and the environment agency who look after obviously environmental matters so here you see a little cartoon where Joe tried a plastic bag you his purpose was good his purpose was to prevent things falling into this open vent whilst the tank was under maintenance but actually it caused a vacuum and the tank actually looked like this that's severe damage thankfully there was nothing in the tank but we prevented a loss of containment there and this could quite easily happen if we don't pay attention to process safety so my first pillar and these are in no particular order of importance they're all important and equally important the first pillar is Safety Management System the second pillar is aging plant the third pillar of compliance to get good process safety is competence of people food pillar is Safety instrumented Systems the fifth pillar is overfill of prevention of overfill the six pillar is secondary and tertiary containment seventh pillar is internal emergency plants eight is external emergency plants 90s process safety performance indicators which I just mentioned in my previous slide and 10th pillar is safety leadership I acknowledge that I've taken this cartoons about Poor Joe from ikemist book an engineer's view of your human error so when competent Authority comes to our site they give us they do an international visit and they give us the following sort of rating and the rating is described so over here the highest score of 50 is not good the lower the score the better it is I've rarely seen scores of 10 or 20. most of the time people are between 30 and 40. it's defined here I don't intend to go through this because you'll have a copy of the slide at the end of presentation but this actually defines what the computer also really rate you against based on what they find and they have a lot of guidance it's not as if they are coming in and just hitting you with an inspection they have very good guidance on each pillar and I will be putting the references for you to look this up in detail should that be of interest to you so if pillar one what's this about safety management system is your daily bread and butter of process safety so we are looking at permit to work systems Safe Systems of work operations maintenance procedures management of change Hazard recognition and reduction safety reports in case of the UK legislation voter risk assessment reports hazards and operability studies etc etc this is a core of process safety if we haven't go to Safety Management that is defined trained out implemented and audited and monitored for any failures or Trends then process safety achieving good process safety is going to be really really difficult another theoretical question for you which of the following disasters for result of poor or total lack of management of change and often many companies do fall down on management of change either they don't recognize it or they don't do something about it or they don't communicate it or they don't complete it in a structured manner so flixpro 1974 28 people unfortunately dead uh this was a wake-up call for the chemical industry in the UK yeah management of change which didn't go to plan far more recently again for me to work system things were changed not communicated out unfortunately quite a large number of people met with death profile toxic gas tragedy in 1984. it's estimated and the figures tend to vary but I've just chosen a middle figure that I came across in my research 8000 immediately that 8 000 people immediately did and this is again management of change Safe Systems of work for me to work lack of Maintenance Safety Systems taken out for maintenance at the same time the process was running and so do you think now this is a question for you to study your your own homework do you think your organizing is good at manually change and if you think yes do justify it if you think no then do something about it right the second pillar is aging plant an aging plant just by the way this tank that you see a picture of a spin decommission is not a live tank but aging plant is not about a rusty old piece of cake aging plant is defined in the HSE guidance about what you do you know about that condition and how that's changing our time and is it still operational has it reached its sort of design parameters say for example if this tank for argument's sake was designed to be six millimeter thick and when you do your cleaning repair maintenance and inspection and you you check that the design parameter was that it should not be used after its three millimeter thick is two millimeter then its aging plant it should be taken out or done something about it replaced there are well known corrosion mechanisms that engineering departments in your companies in my company deal with daily and take actions to prevent or minimize this and the ultimate aim of process safety I would say is two words prevent loss of containment if your toxic hazardous corrosive liquid is in containment there's no problem with it the moment you lose it intentionally or unintentionally then the consequences arise so in case you're wondering what causes plant to age these are some of the reasons not an exhaustive list but you have corrosion you have stress you have erosion your fatigue your embrittlement your physical damage in concrete which you think is more permanent you can get spalling due to atmospheric corrosion or moisture in Grass your subsidence your weathering your expansion contraction due to Thermal changes daily weather changes you have instruments that drift that no longer show the correct readings you can have dry joints within sensitive level instruments you can have detector poisoning these are only some there are lots of causes and to keep on top of Aging plant is again plant preventive maintenance understanding what the equipment is designed for preventing any excursions behind the design limits and so on these aging mechanisms can affect primary containment the tanks themselves and pipelines as well as supporting structures that's also important to understand if you maintain your pipeline and your tanks that's not sufficient you also need to look at what's keeping the pipeline stable what's preventing from falling down or if it's Underground how do you monitor underground pipelines for corrosion do you do regular big runs do you do you review the information once you've done the test or is it just something on a tick box so all these things bring up these issues the third pillar is about competence and very important that is when you ask someone what is competence and people usually say oh it's training and experience ability to do a task according to standard procedures who do you call ability to respond to the pressure competence yeah definitely here is for you again from the same reference you'll left the Joe for a minute while draining water this is a typical operation in gas Industries oil Industries and even chemical Industries so what you do is remove the water hopefully not on the floor as Joe is staying here but in this case Joe left a minute do something maybe he was called out or he had some other task to attend and by the time he came back there's a big fire roaring there because it's a flame no liquid and disco fire so the in the coma regulations control of major excellent accident has it has regulations which apply in the United Kingdom and across Europe as Services regulations competency is actually very important and the competency is not just training experience and how they perform it starts with recruitment are you recruiting correct candidates ask yourself get involved with the HR it's not just recruiting a person you're recruiting a person with the right attitude and the right skills and if they haven't got the skills how will you go about providing those skills all this and much more the ability to carry out in my opinion safety critical tasks correctly every time is the key processator requirement so just to give you some more homework which of these three options do you think is a safety digital task safety induction of visitors to your site line breaking for maintenance so this is operational pipeline I'm talking about or wearing correct personal protective equipment and the clue to the answers would be what is the consequence if the visitors are not inducted are they going to go and have a quiet cigarette in a highly flammable and toxic atmosphere just just a ridiculous example or when you're breaking line is the line under pressure and what is the liquid which will come out what is the consequence so these are the questions you ask and there's definite guidance in the on the HAC website in the UK on safety critical tasks and how do you go about measuring it how do you go about identifying it what do you do about it I would urge you to read the guidance next one is about safety instrumented systems prevention of loss of containment and foreign explosion is based on reliability of safety instrumented systems or their the acronym in our wonderful Industries sis an example of such equipment is shown here where this is level gauge which alarms when the tank capacity is reached so we are filling up this tank it reaches preset high level and it allows but it's it's not sufficient have a look at your own safety instrumented systems if it's just alarming and it's relying on someone to listen to the alarm and react to it a do they have sufficient time to do that in and B can it be further automated and wonderful it would be wonderful and very good for process safety to prevent loss of containment overfilling if the radar not only alarms it also actually shuts down the inlet to the vessel makes sense you are going to design the hazard out you have overfilled fair enough you shouldn't have done that in the first place if your operators were competent but if the worst happens what is your layer of protection there another example is in oil storage industry Interceptor pollution Pros which alarm and in good cases with good design and with a good investment it actually shuts down the final wall so you not only low something is wrong but you also have an assurance that the pollution the polluting liquid is not going to enter public water courses and kill fish and Aquatic environment ah my favorite is pillar five if you look at most of the incidents they are due to overfill in at least in our oil and gas and storage Industries so here is a clip from one of the csb incidents or fill of tank is one of the most common process safety event that might lead to fire explosion or severe consumption the factors we must get right is are people competent and following say for example root cards which say okay now I'm going to divert the flow from the ship to tank number one tank number one is nearly full so I need to go to tank number two but before I do that I need to shut these walls in that order so this is clear procedures training and experience if you don't have that very easy to overfill because you might root your ship's input to the wrong tank which is already full so it's got nowhere else to go it will just come out from somewhere use of Maintenance systems to inspect and proof test all safety critical planting equipment so going back to safety critical plant how do you identify there's some really good guidance on the energy Institute website and I shall provide links when the final version of this presentation is uploaded for your access and use in the UK we have what's known as a containment policy scorecard that actually forces us as operators to look at do we have primary containment do we have secondary containment containment are this good enough or not and then these scorecards when they are filled in are reviewed by the environment agency and the HSA and then you can have a plan if you are deficient in some areas to improve it unless you measure it you can't improve it that's the universal truth and here's pillar number six so we have secondary internship containment serious 764 which I mentioned below the figure is a very good guidance it's freely available on the website so please type in Syria 764 guidance and it will give you a link to download this guidance it's very comprehensive and it's it's excellent it is really good practice I would say so some of the terms that I'm using secondary containment so what that means is you have a tank for example the tank here and if it was to lose its contents for whatever reason maybe airplane strike or something ridiculous or maybe a while that's a sheared off because of Aging lack of Maintenance or poor design then are the contents of this tank going to go all over and pollute nearby reverse watercourses or are they going to be contained in a Bund so this bond is a secondary containment so your primary containment is the vessel itself secondary containment is the bond and say for example the bond is to be designed to Syria guidelines which say 110 percent of the largest tank in that or could be 125 percent of the largest tank in a group if compound is not able to contain it then it can overflow go through the drains into the water courses so in in such cases what you can also have is so this is like a backup to a backup to a backup you can have crochet containment so the sites could be designed that old drains speed to Interceptor and anything going from the Interceptor or anything outside the Interceptor could be captured on a low-lying lagoon I understand that it's not possible for this sort of containment to be built on smaller sites but for the larger size and proportionate to the loss of containment consequences whether it's toxic pollution or fire or explosion if you run a hazardous site then you must provide this or measure yourself and this gives an indication of how good you are at your process Safety Management tertiary containment is container for product which is over top now there are other scenarios so for example there is a fire in this band is this tank walk figure one there's a fire and it's been cooled down by firefighters from a safe distance so you got hydrocarbon releasing that one and you've got water coming over so what's going to happen is the wind is gonna even though it's designed to 110 of the capacity it's going to run over and running over hydrocarbons normally are lighter than water so they will come over and they'll go to wherever they will go and with the fire there'll be like a running fire pool going all around the side There's a Nightmare scenario so again having these sort of arrangements and serious 764 will guide you to more more help detailed help detailed technical help my pillar number seven is internal emergency plants so in the UK we have the first two aspects to internal emergency plant which is major accident prevention policy so this is a commitment from the most senior uh levels of your company that you will take measures to prevent major accident so major accident is different to a normal accident I won't call an accident normal but uh just to be clear major accident is multiple fatalities severe fire toxic cloud smoke going over public areas Etc the second tool that's used in internal emergency plants and there is very good UK guidance although it's applicable to UK and the parent Wars and services applicable to all over Europe there's nothing preventing you from looking at the guidance the guidance is coma approved code of practice l111 I shall be providing links to those for you for your use later on so there's something called prz so piz stands for public information zone so when our competent Authority receives safety report from us as an operator to actually review it they do predictive calculations of a fire event so say we were to have a jet file a pool fire how far the thermal radiation will be going and who will it harm So based on that they would establish public information Zone so then there's a legal Duty on us as an operator to write to the public who might be affected by whatever happens on our event and this is very important because if you refer to some of the chemical safety board incident videos people in the neighborhood really didn't know what was going off in the factory they thought it's just a normal Factory but when something went wrong there it actually affected the locality around them the sites the another Point within internal emergency plans is exercises invite your local fire brigade who are usually the First Responders to come on your site have a look at what you have and do some sort of tabletop exercises or even on-site exercises with them to understand how they would respond and what are the things that would make their life easy an example of this could be if you have fire water mains on your site which you want to use the fire we get to use when they are on site because they might not have enough water in their tankers is to make sure that your host fittings match what's on your side so they can very quickly without delay connect to that and use your fire water emergency procedures once they are written should be reviewed and every time you review it or do an exercise you should make changes if required my pillar 8 is external emergency plants so again this is specific to the UK you might have your own regulations do check them when you start talking about process safety external emergency plants actually the responsibility for developing this lies with the local Authority and it has input and consultation with all emergency responders So within the UK the fire brigade the police the ambulance the public health England the health and safety executive environment agency highways Authority Water Authority and so on and also Community groups they all are consulted so what this means is we as operators give scenarios what could go wrong realistically not be ridiculous but realistically we give the scenarios to the local Authority and the local authorism when consults all these statutory consultants and then works out a plan on how they would risk what is their role what is their responsibility and their legal responsibility within the UK under the coma regulations that I keep on mentioning it's it's a little exercise for an operator they must do one every three years so every three years there will be an external emergency plan as an example and on one of our sites we are 110 people and they have different roles so the some are players so these people are not aware of what the scenario is until the day of the exercise then you have umpires who can provide information should the agency ask so for example if a fire brigade asks me where do I turn off Electric Supply to this area which is affected then umpire is a knowledgeable person with the site knowledge who tells them yeah you go to this place and that that's why you can safely turn it off and so on they have observers observers are neutral people they also have people follow the plan what were the improvements required what's the communication okay what did go wrong and what did go well so at the conclusion there's like a hot deep riff for 15 minutes everyone then chips in with their uh information and say yeah that went well we could improve on this and then there is a formal called debrief this is all part of the regulations under control of major accident hazards and this is our pillar eight the aim of this exercise is to validate the plan and completely improve it so the moment you think you go to a perfect plan that's the moment the downfall begins next I mentioned the process safety performance indicators and again there are very good guidance documents from the center for chemical process safety in America our own HSC has HSC 254 which gives you a full guidance in Crystal Clear language without technical jargon or how do you go about identifying and setting up processivity performance indicators so these are the indicators if you go back to the triangle if you refer to the triangle which I showed you earlier on these are the ones which actually will indicate to Senior Management fought my risk controls are doing are this effective are there any issues with my process safety controls my risk control systems and this could be two types it could be lagging which means something's gone wrong and you're going to learn from it or it will be leading and it's important to understand you can't just have leading indicators you must also learn from lagging indicators if you don't learn from your learning industry your process safety incidents as I call them then you will never get a true picture so typically risk control systems are operator competence so again one of my first management first pillar of compliance Safety Management System operational procedures do have procedures how do you train your Cooperators against these procedures are these procedures audited do what you do you do what you say you would do or two people develop their own systems of work they're little shortcuts which might be it might be good for making the work go faster or completing a job with less hassle but might not be correct process safety procedures we have seen examples of Joe living unattended draining of the tank that's a typical one procedure might say you will stand by that tank until you drain water and not go away the moment a moment's hesitation could lead to incidents so as I said the process safety indicators could be proactive which is good practice such as plan priority maintenance so that's very easy to set for you isn't it if you have planned period maintenance system especially if it's computer based you know for say for the month of April that's just gone by you had 30 plan priority maintenance tasks and after the month has gone you look at that and you say okay I managed to complete 20 of the 30. my target was 25 as a minimum so you know that I'm falling behind with my figurative maintenance so that again is an indicator of danger you are not maintaining your plant you're not maintaining your plant integrity and that can lead to loss of containment so again some homework question for you to think about can you think of what else would be a good process safety indicator last but not the least as I said in one of my safety triangles the core of good process safety is leadership leadership by saying leadership I don't meet managers I mean the actual senior leaders of the company the board members the executive members of the company Okay so they need to be fully aware of what process safety is how process safety is managed and if there are any breaches of process safety vote is being done about it how do you continuously improve your process safety o and m means operations and maintenance team they pay play a key role and there's an eternal fight between operations and maintenance and most companies that I know of yours might be an exception so my apologies but most companies operations take precedent or maintenance a maintenance person says you are due for preventing maintenance I need that piece of Kit to refurbish check inspect and reinstate and operations no too busy need to provide the customer with the goods go away that is not the type of dialogue that leads to good process safety leadership so the serial relationship teams if the board members actually go to the site and talk to the people and talk to the operators what are the process safety issues so that search two purposes one is it becomes a two-way conversation and also it raises the awareness of the process safety operators the plant operators who can then relate their tasks to the key process safety failures or Consequences and and consequently be more efficient be more aware to summarize process safety is different compared to occupational safety process safety relates to safe operation of the plant to minimize the potential for fire explosion or environmental contamination and remember all three could happen at the same time process Safety Management involves a lot of different aspects where competency of operators understanding of control measures risk control measures understanding what to do in abnormal process conditions safety critical maintenance are some of the key issues they must be managed by all employees and management now one of the things I would like to mention and maybe um preempting myself is this is a tester session where I've just flown through each every topic depending on the feedback we would like to take this further and then have individual sessions on each pillar of compliance so please when you give us feedback do tell us if you'd like some more of the same there's a video which will try and sort our technical issues with but basically this video is this poem and it's quite a powerful poem it's a poem by Don Muriel after an actual incident and it goes I could have saved a life that day but I chose to look the other way it wasn't that I didn't care I had the time I was there but I didn't want to seem a fool or argue over a safety rule I knew he'd done the job before and if I spoke he might get oh the chances didn't seem that bad I'd done the same I'd taken some chances he knew I had so I shook my head and walked on by he knew the risks as well as I he took the chance I closed an eye and with that act I let him die I could have saved life the day but I chose to look the other way now every time I see his wife I know I should have saved his life that guilt is something I must bear but it isn't something you need to share if you see a risk that others take that puts their health or life at stake the question asked or thing you say could help them live another day if you see a risk and walk away then I hope never have to say I could have saved a life that day but I chose to look the other way thank you for your time over to Simon okay should I thank you very much for that um I've got a number of questions here some have received directly um from the people there so I want to read through them at the time we've got left and obviously any that we don't get the time to go through we'll we'll make sure we answer in the in the in what is then posted online so so the first one is at the top of the list I think the one that's coming most recently yeah the uh the delicate apologize if you if you mentioned this earlier but which of the PSM standards are more widely used in the UK in the UK we tend to use the energy Institute of process safety framework okay and there is a lot of guidance on the HSE website under coma regulations uh which then mentions different standards okay we obviously don't use the OSHA one but yeah but they're very similar okay the elements are very similar osm has 11 different so 12 different elements but we covered some of the elements within one of our pillars okay okay thank you specialist the next one and it touches on one of those it's one of these subjects that when I hear the two words put together in the same sentence I get the hairs on the back of my next stand up change management Yeah you mentioned that earlier um about how the importance of it and how not many people do it right and I I absolutely agree with you on that one is there anything certainly in the process safety World any guidance on that that the delegates could have a look at even if they're not in the process of the world that actually maybe there's some principles there that they could be looking at tying into their own system yes certainly I think most uh most regulator sites and I can mention the HSC has got uh good guidance on them and there's also a very good book by the American chemicals societies ccps guidance for process safety yeah Center for chemical process safety that's specifically on Monument of change okay it's a very good guidance and can be used you might have to download or purchase it okay again the safe work Australia Canadian occupational and process safety there's a lot of guidance available and the thing to do is not to make it more complicated so that people find it difficult to follow what you should do is keep it simple stupid as they say yes I like saying this cliches because they're great oh he said stupid you're talking directly to me then but okay no no um the next the next one you talked about maintenance schedules yeah and obviously the use of them underneath them in process safety and I'm I'm kind of adding my thoughts into it here but I'm guessing that the building of your maintenance system you're probably going to tie that into the hazards that you do to identify the critical elements of your plan to help prioritize yeah is that right because you embellish on that a bit more your your own approach to maintenance schedules and how you would build them for us we first thing we've done is we've taken the human element of guesswork out by having a structured specific software and there's lots of software available from different sources and what plant previously maintenance does is it first of all it access your asset resistor you know exactly what you have and then you build in routines into your maintenance system the software allows you to put in procedures so and this procedure should be taken from the design and operation guidance which is supplied with your equipment so for example if you have a pressure vessel the pressure vessel then will say this is my design pressure I should be tested every three years using this standard method so there is no variation there's no guesswork so that is the approach I would take for preventive maintenance regging so it's identify your assets put them electronically and then Institute checks now doing more of maintenance is not necessarily good it should be risk based and again on the HSE website if you Google search you will find risk-based inspection and there's a lot of information fortunately we now live in an age where information is not restricted to paper copies everything is there yeah Google tells us and I guess being based with space that's where your hazard comes in and that it's going to identify and properly prioritize yeah that's it fantastic uh we've got we've got another question come in um just any guidance on the is there any guidance on the approach to develop and introduce PSN in a company where this would be a New Concept Yes Energy Institute pressure safety framework it's a very good document to refer to and I shall provide a link to that okay and some of the Publications within those are chargeable but most of it is sort of freely available to public within this they've taken each element of process safety and given more detailed guidance so you have the oral framework and then you can go into each element one such example is safety critical identifying your safety critical equipment and then it tells you what to do about it once you identified yeah okay fantastic um another thing that you and you mentioned you mentioned this and it's obviously quite a hot topic for us in the offshore world with them emergency plans and the testing of emergency plans obviously in the offshore world and the Marine World that's something that that we're required to do and required to test and I'm just wandering from a personal perspective what how that's what that looks like in on the in the onshore world and how often you have to do it is that driven by external factors or is that something that you determine for yourself or yeah the external emergency plants are stretched to a requirement every three years but internal emergency plan is left to the companies on devices so you look at your hazard and see uh have you got a sense of disquiet about it then you do it more often okay what you also do is it should be proportionate to the hazards you hold for our sites which are just basic storage and transfer of fuel it's different from a say a pharmaceutical site which holds highly toxic chemicals and it mediates sure for them the internal emergency plants are are really critical because the first effect would be on the people nearby if you take Bhopal tragedy for example there the release of methyl isocyanate killed so many people and it went offside as well over there for them doing those scenarios even if it's just a couple of hours you just grab people at random and say I've just got this scenario I've lost this toxic chemical what's the thing you're going to do just very simple and that should be good and then for further guidance again there is specific guidance by the HSE on emergency plants okay I shall put in reference for that right brilliant thank you another couple of questions come in um next on what defines safety critical equipment under coma under that if that's an equipment the failure is a one of your major accident scenarios that's safety critical equivalent so take for example a very simple approach would be if you have bulk tanks and there's a level gauge on it that's this safety critical because all your responses your last layer of protection when the level gauge if that level gauge fails you are likely to have an overfill scenario that might lead to if it's a toxic or very highly flammable liquid of our scenario okay so that would be so if you take the classic bunsfield example the failure of the level switch led to the Fine explosion we were very fortunate that no one was killed had it happen not on a Sunday morning early in the morning had it happened during peak time there were thousands of residents and offices nearby and you've seen the devastation just look a monthly and tells you so that is an example of safety critical equipment great thank you Josh uh the next one what models or tools have you seen that help to summarize the vast amount of data on process safety health status to Senior Management whose time is precious that helps them understand where to allocate the resources I guess that's a great question isn't it that um no we we are safe professionals we love to talk about we love to have lots of data don't we in spreadsheets and charts but obviously the people that we're presenting that to they have a very short attention span occasionally in a very short amount of time to consider it so what tools or what or tips would you give for that that's pillar nine process safety performance indicators and HSC 254 is a Bible I really like that publication because it lays it out right from beginning about what is about to the final summary now there are companies for example uh Scottish Power they have got a very elaborate dspi tool which is software and it's wonderful and it throws a lot of attention to you but there's nothing stopping you a medium or a small size company from developing a spreadsheet which then month on month is reviewed at the board meetings it will only take say 15 minutes and it it just gives you a red green or blue status so sorry red green and yellow status yeah yeah so bread means the trend is downwards what so that then flags up the senior Management's attention why is just as a classic example why is the pipeline inspection falling behind it's so critical to maintain this pipeline which contains a high pressure toxic corrosive fluid so that is a key initiator of a major accident on the side so why are we not doing that and that's the way to get grab board's attention color coding keep it simple and keep it focused and the other thing which many companies do go down at a tangent with is process safety performance indicator maximum should be six to eight in a very complex refined business or offshore business such as yours I understand appreciate that you could have lots of key hazards and key indicators so the one way to do would be to rotate look at say you choose first six look at that over three months and you see there is no difference discard them start again with different ones and that is the way you can break it down and keep it simple otherwise yeah process safety performance indicator report could be 20 pages long and node yeah looking at it sure except for the person who produced um really good question from Rajesh um any other are there any recognized training courses or diplomas as such on PSN oh yes if you are based in the UK there's a gold standard process safety awareness course and it's provided by cogent skills okay and there are different levels there is process safety for leadership and I've done one of those and this is very good so code and skills are a provider of training but they don't actually do the training they have quite a number of certified training companies and training providers so that is something you could look at yeah and there are process safety for operators there's also a train the trainer course so for a company with say number of sites it's not practical to take everyone out so what you do is you you take usually people from Assurance or maintenance stuff you train them to deliver the process safety for operators training and I also understand that nibosh is working with iOS yeah to develop a course on processing okay okay rejections followed that by saying I think I'm guessing he's based in the UAE in the United States [Laughter] but yes there are courses which again U.S websites Center for chemical process safety can also provide correspondent courses okay and you can be certified okay fantastic thank you um going on to I think the final question we've got on here again going back to the one we were talking about indicators um questions simply being more leading or lagging indicators so it should be a proportionate mix for both you can't just rely on leading and you can't just be on a leg if you're relying on legging you having too many incidents I would not Advocate that one so it should be a good mix of both and again what I would say to you is if you had a process safety incident and the process safety incidents I also live behind in the American Standard API 570 there is a tier one which is a major major one there's a tier two and there's a tier three so tier three is minor so you you could sort of monitor these sort of lagging indicators and comparing it and saying okay we had three tier ones then there's something definitely wrong or we have had 20 tier threes but no tier twos or no tier ones Ah that's good we are having minor as fact of life that loss of content will happen but if you spill one liter of a non-toxic non-hazardous liquid that's different to hundred thousand liters going down the river absolutely absolutely fantastic thank you I think that's all the questions we've got on things so you you can you can sit back in your chair now I think I can only thank you from a personal level collection is something that I I came into this not as interested I think as all the other delegates or something not something I considered myself to be particularly strong in so you've given me a great Insight that wasn't personal level as much and also obviously as a representative of the offshore group here today genuinely appreciate you offering that to our members as well as your own I think it's been a fantastic insight into what is obviously a very complicated and but also you know but like you we were talking earlier but something that a lot of us do without even realizing it's probably process safe that's right I generally appreciate your your input on that so thank you very much indeed just a few things left to say from that from a housekeeping perspective I'm led to believe by Ben my colleague to my left that's obviously the presentation will be available towards the end of the week hopefully by Friday at the latest it'll be available to you also and that'll be available both On the Hazardous Industries and the offshore group internet pages so please keep an eye out for that just a couple of other things to say before we bring this to a close um this is as shalesh mentioned this is the first of the seminars we've done together we're very hopeful of doing some more ones so please keep an eye on connect please keep an eye on on our mutual event Pages just for the next ones that are announced as and when they're arranged um the Hazardous Industries group webpage I believe is being updated as we speak with their events page in particular so please do keep an eye out for their events I know they're planning currently and from the offshore with respect of our next event is on Monday coming which is the 15th and that's back in Aberdeen where we're doing one on the life of a safety rep obviously as our offshore members on the line will know that it's been a very challenging time for the offshore industry so we get the Insight of two representatives from Step change and they're G18 safety reps committee to come and talk about what it's been like for the last couple of years under very challenging conditions so we have Shane and Dave from the G18 come along to do that so obviously all are welcome so if you're in if you're in Aberdeen please do come along and say hello to us I will be there myself and look forward to seeing you all there and just to say also that the offshore group annual conference we've now got a confirmation of the date it's going to be this it's going to be in October the 19th of October it's going to be at the Discovery Museum in Dundee and please do keep an eye out for it we'll be posting some details on that very soon we've already got confirmations from a number of speakers including representatives from the HSE and the hsl so please do keep an eye out for that and you'll see more Communications over the coming weeks all that's left for me to say is thank you to everybody for for taking the time to dial in today thank you for everybody for raising the questions that you have thank you to shirlesh again for the effort he's put into the presentation he's done today and to Ben and iosh for facilitating this for us and we look forward to seeing you soon thank you very much

foreign good afternoon everybody my name&#39;s Simon hatz and I&#39;m the current chair of the offshore group and I have the pleasure of hosting today um just to just a few things before before I hand over to sholesh our speaker for the day um for those of you who are already members of the group you will know that this is the third webinar that the offshore group have been involved in and I thank you all for for attending um this is actually the first joint event that we&#39;ve done with the Hazardous Industry Group and I think that the Hazardous Industry Group for doing this with us and they&#39;ve been a fantastic support throughout and shirlesh your speaker is a member of that committee and so I thank you in advance for what he&#39;s about to speak about um hopefully all being well this will be the first in a series of webinars that between the two between the two groups we will look to put on for you but obviously that will be dependent upon the feedback we get from yourselves so as Ben rightly said throughout the session if you do have questions if you do have comments please do take the time to raise them and and also following the event you will get the opportunity to raise some feedback and to generate some feedback coming out the event and what I would say to you is that that will be read and analyzed both by both ourselves and the Hazardous Industry Group so please do take the time to feedback to us your opinion genuinely does matter and it will genuinely determine what we look to do moving forward so if you could take the time to do that when the opportunity arises would be very grateful as Ben said um please raise your questions throughout the event and what we will do we&#39;ll do the question and answers at the end I&#39;ll I&#39;ll pose the questions to chalesh and obviously and hopefully try and get the answers that you were looking for my final thing to say and I&#39;m really Keen not to take it too much time away from shalesh is just to say this everybody who&#39;s who&#39;s dialed in today you&#39;ve all done so for a reason I don&#39;t know what that reason is but I&#39;d imagine there&#39;s something within the content that you are hoping to learn whether it&#39;s a question you&#39;ve always want answered or something you wanted a bit more insight into so you do have the ability to raise questions so please if there is a question that that you have that hasn&#39;t been answered especially towards the end of the presentation please do take the time to raise it because I would hate for any of you who have taken the time to dial in to leave the today&#39;s session without the answers you were looking for so without further Ado I will hand over to chalesh who will take you through his presentation good morning good afternoon and good evening my listeners first of all may I please thank you for your time and the interest you&#39;ve shown in this presentation uh as for the title it is about awareness it&#39;s not the full monty as they say for process safety but it&#39;s a beginner&#39;s guide and in this one I&#39;ll be using various standards now the first picture I have is is a small clip some of you may have seen it apologies to those who have seen it before but this gives you a clue as to what we&#39;ll be talking about later on there&#39;s no sound on it so please don&#39;t turn a volume on your uh on your screen please there she comes again Hallelujah so this is going back so the question I&#39;m asking is what do you think led to this incident now I don&#39;t expect an answer straight away but it&#39;s to do with electrostatic charge and in process safety this is a source of ignition moving on now my objectives for this session is to Define what process safety is explain the difference between occupational safety and process safety describe the 10 pillars of compliance approach which I&#39;m going to follow there are various standards as people who may be aware there&#39;s the OSHA process Safety Management standard there is also a very good energy Institute guidance on process safety framework but for the purpose of this session to keep it simple and very much targeted I&#39;m going to use the 10 pillars of compliance approach which is applicable to any process Safety Management System it&#39;s a very basic and simple process and this is the approach which the UK Regulators health and safety executive have followed so when they come on one of the sites which are grown by control of major accident Hazard regulations they follow this approach so I&#39;m sticking to that one makes life easy for us I&#39;m going to outline consequences of process safety failures with a few examples and I&#39;m going to highlight the key part played by human factors in achieving high pressure safety standards so thankfully human interaction is very good and it&#39;s very essential in achieving process safety most of the stuff that I&#39;m going to talk about will not come as a surprise to you you&#39;ve already do that as just explaining the link what is process safety social safety generally refers to prevention of unintentional releases of chemicals energy or other potentially dangerous materials during course of a chemical process that can have a serious effect on the plant in the environment process safety for example involves for prevention of leaks spills equipment malfunction over pressures over temperature corrosion metal fatigue and other similar conditions process safety programs actually focus on design and Engineering facilities maintenance of equipment effective alarms effective control points procedures and training in other words everything we do on the actual Hardware on the equipment that we have it&#39;s sometimes useful to consider process safety as an outcome or result of a wide variety of technical management and operational disciplines they all come together in organized way to give us a safe outcome the figure next to it gives you like a very broad view of what&#39;s involved and the Heart of this processity will as I like to call it is management leadership and just to stress that point let&#39;s talk about the differences between personal safety which I would say is occupational safety and process safety so if we look at the typical safety triangle hopefully you would have seen this so there&#39;s Health environment and safety the same triangle on both sides but in occupational safety or personal safety we tend to construct more on preventing harm to people on people&#39;s health and to people&#39;s safety for example we wouldn&#39;t be running dangerous machines with chop off people&#39;s fingers without inadequate with inadequate guarding Etc but in process safety we consider it more on preventing losses or long-term harm to the environment and also the safety so we&#39;re talking about fires and explosions here okay how how do we do this what are the little indicators of danger that&#39;s my favorite saying what are little indicators of danger in personal safety and process safety so if we look at the figure the triangle there so examples of getting personal safety wrong are injuries manual handling exposure and in process safety the examples could be fire explosion pollution Etc if you look at the typical triangle the focus on personal safety is picking it up very early on so you get lots of near misses you get lots of minor incidents and if you don&#39;t some do something about it you could get serious incident and haven&#39;t forbid a fatality but in process safety is the other way around the unless you are very much focused on process safety and do your process safety uh performance monitoring rigidly and rigorously then until something goes wrong such as a serious accident or a fatality you have no clue that things are not running right so it&#39;s very important and this is one of the pillars of process safety which I&#39;ll explain later on moving on to control the hazard for personal safety we actually we should focus on elimination and substitution but usually it&#39;s very easier to say here wear this hard at and you&#39;ll prevent injuries to your head where this safety goggles to your eyes will not be taken out by a corrosive chemical so these are administrative and PP and people often go for these controls and they they are in the hands of the front line workers operators and supervisors but whereas in process safety notice responsibility to Hazard control is hands of Senior Management and Engineers so elimination and Engineering are the first preferred choices PPE will not stop a process safety incident and that&#39;s an important difference but to be quite Frank there&#39;s no dividing line between the two types and we must get both of them right overall objective is in an industrial setting in a work setting you don&#39;t want to harm the people you don&#39;t want to burn down the Plant and you don&#39;t want to cause Finance lotions or severe environmental pollution I hope that is pretty obvious for all of us so here are my wonderful 10 pillars of compliance so this is a list of 10 pillars of compliance which is followed by the competent Authority within the United Kingdom so it consists that the competent authority comprises of the health and safety executive who look after safety and health and the environment agency who look after obviously environmental matters so here you see a little cartoon where Joe tried a plastic bag you his purpose was good his purpose was to prevent things falling into this open vent whilst the tank was under maintenance but actually it caused a vacuum and the tank actually looked like this that&#39;s severe damage thankfully there was nothing in the tank but we prevented a loss of containment there and this could quite easily happen if we don&#39;t pay attention to process safety so my first pillar and these are in no particular order of importance they&#39;re all important and equally important the first pillar is Safety Management System the second pillar is aging plant the third pillar of compliance to get good process safety is competence of people food pillar is Safety instrumented Systems the fifth pillar is overfill of prevention of overfill the six pillar is secondary and tertiary containment seventh pillar is internal emergency plants eight is external emergency plants 90s process safety performance indicators which I just mentioned in my previous slide and 10th pillar is safety leadership I acknowledge that I&#39;ve taken this cartoons about Poor Joe from ikemist book an engineer&#39;s view of your human error so when competent Authority comes to our site they give us they do an international visit and they give us the following sort of rating and the rating is described so over here the highest score of 50 is not good the lower the score the better it is I&#39;ve rarely seen scores of 10 or 20. most of the time people are between 30 and 40. it&#39;s defined here I don&#39;t intend to go through this because you&#39;ll have a copy of the slide at the end of presentation but this actually defines what the computer also really rate you against based on what they find and they have a lot of guidance it&#39;s not as if they are coming in and just hitting you with an inspection they have very good guidance on each pillar and I will be putting the references for you to look this up in detail should that be of interest to you so if pillar one what&#39;s this about safety management system is your daily bread and butter of process safety so we are looking at permit to work systems Safe Systems of work operations maintenance procedures management of change Hazard recognition and reduction safety reports in case of the UK legislation voter risk assessment reports hazards and operability studies etc etc this is a core of process safety if we haven&#39;t go to Safety Management that is defined trained out implemented and audited and monitored for any failures or Trends then process safety achieving good process safety is going to be really really difficult another theoretical question for you which of the following disasters for result of poor or total lack of management of change and often many companies do fall down on management of change either they don&#39;t recognize it or they don&#39;t do something about it or they don&#39;t communicate it or they don&#39;t complete it in a structured manner so flixpro 1974 28 people unfortunately dead uh this was a wake-up call for the chemical industry in the UK yeah management of change which didn&#39;t go to plan far more recently again for me to work system things were changed not communicated out unfortunately quite a large number of people met with death profile toxic gas tragedy in 1984. it&#39;s estimated and the figures tend to vary but I&#39;ve just chosen a middle figure that I came across in my research 8000 immediately that 8 000 people immediately did and this is again management of change Safe Systems of work for me to work lack of Maintenance Safety Systems taken out for maintenance at the same time the process was running and so do you think now this is a question for you to study your your own homework do you think your organizing is good at manually change and if you think yes do justify it if you think no then do something about it right the second pillar is aging plant an aging plant just by the way this tank that you see a picture of a spin decommission is not a live tank but aging plant is not about a rusty old piece of cake aging plant is defined in the HSE guidance about what you do you know about that condition and how that&#39;s changing our time and is it still operational has it reached its sort of design parameters say for example if this tank for argument&#39;s sake was designed to be six millimeter thick and when you do your cleaning repair maintenance and inspection and you you check that the design parameter was that it should not be used after its three millimeter thick is two millimeter then its aging plant it should be taken out or done something about it replaced there are well known corrosion mechanisms that engineering departments in your companies in my company deal with daily and take actions to prevent or minimize this and the ultimate aim of process safety I would say is two words prevent loss of containment if your toxic hazardous corrosive liquid is in containment there&#39;s no problem with it the moment you lose it intentionally or unintentionally then the consequences arise so in case you&#39;re wondering what causes plant to age these are some of the reasons not an exhaustive list but you have corrosion you have stress you have erosion your fatigue your embrittlement your physical damage in concrete which you think is more permanent you can get spalling due to atmospheric corrosion or moisture in Grass your subsidence your weathering your expansion contraction due to Thermal changes daily weather changes you have instruments that drift that no longer show the correct readings you can have dry joints within sensitive level instruments you can have detector poisoning these are only some there are lots of causes and to keep on top of Aging plant is again plant preventive maintenance understanding what the equipment is designed for preventing any excursions behind the design limits and so on these aging mechanisms can affect primary containment the tanks themselves and pipelines as well as supporting structures that&#39;s also important to understand if you maintain your pipeline and your tanks that&#39;s not sufficient you also need to look at what&#39;s keeping the pipeline stable what&#39;s preventing from falling down or if it&#39;s Underground how do you monitor underground pipelines for corrosion do you do regular big runs do you do you review the information once you&#39;ve done the test or is it just something on a tick box so all these things bring up these issues the third pillar is about competence and very important that is when you ask someone what is competence and people usually say oh it&#39;s training and experience ability to do a task according to standard procedures who do you call ability to respond to the pressure competence yeah definitely here is for you again from the same reference you&#39;ll left the Joe for a minute while draining water this is a typical operation in gas Industries oil Industries and even chemical Industries so what you do is remove the water hopefully not on the floor as Joe is staying here but in this case Joe left a minute do something maybe he was called out or he had some other task to attend and by the time he came back there&#39;s a big fire roaring there because it&#39;s a flame no liquid and disco fire so the in the coma regulations control of major excellent accident has it has regulations which apply in the United Kingdom and across Europe as Services regulations competency is actually very important and the competency is not just training experience and how they perform it starts with recruitment are you recruiting correct candidates ask yourself get involved with the HR it&#39;s not just recruiting a person you&#39;re recruiting a person with the right attitude and the right skills and if they haven&#39;t got the skills how will you go about providing those skills all this and much more the ability to carry out in my opinion safety critical tasks correctly every time is the key processator requirement so just to give you some more homework which of these three options do you think is a safety digital task safety induction of visitors to your site line breaking for maintenance so this is operational pipeline I&#39;m talking about or wearing correct personal protective equipment and the clue to the answers would be what is the consequence if the visitors are not inducted are they going to go and have a quiet cigarette in a highly flammable and toxic atmosphere just just a ridiculous example or when you&#39;re breaking line is the line under pressure and what is the liquid which will come out what is the consequence so these are the questions you ask and there&#39;s definite guidance in the on the HAC website in the UK on safety critical tasks and how do you go about measuring it how do you go about identifying it what do you do about it I would urge you to read the guidance next one is about safety instrumented systems prevention of loss of containment and foreign explosion is based on reliability of safety instrumented systems or their the acronym in our wonderful Industries sis an example of such equipment is shown here where this is level gauge which alarms when the tank capacity is reached so we are filling up this tank it reaches preset high level and it allows but it&#39;s it&#39;s not sufficient have a look at your own safety instrumented systems if it&#39;s just alarming and it&#39;s relying on someone to listen to the alarm and react to it a do they have sufficient time to do that in and B can it be further automated and wonderful it would be wonderful and very good for process safety to prevent loss of containment overfilling if the radar not only alarms it also actually shuts down the inlet to the vessel makes sense you are going to design the hazard out you have overfilled fair enough you shouldn&#39;t have done that in the first place if your operators were competent but if the worst happens what is your layer of protection there another example is in oil storage industry Interceptor pollution Pros which alarm and in good cases with good design and with a good investment it actually shuts down the final wall so you not only low something is wrong but you also have an assurance that the pollution the polluting liquid is not going to enter public water courses and kill fish and Aquatic environment ah my favorite is pillar five if you look at most of the incidents they are due to overfill in at least in our oil and gas and storage Industries so here is a clip from one of the csb incidents or fill of tank is one of the most common process safety event that might lead to fire explosion or severe consumption the factors we must get right is are people competent and following say for example root cards which say okay now I&#39;m going to divert the flow from the ship to tank number one tank number one is nearly full so I need to go to tank number two but before I do that I need to shut these walls in that order so this is clear procedures training and experience if you don&#39;t have that very easy to overfill because you might root your ship&#39;s input to the wrong tank which is already full so it&#39;s got nowhere else to go it will just come out from somewhere use of Maintenance systems to inspect and proof test all safety critical planting equipment so going back to safety critical plant how do you identify there&#39;s some really good guidance on the energy Institute website and I shall provide links when the final version of this presentation is uploaded for your access and use in the UK we have what&#39;s known as a containment policy scorecard that actually forces us as operators to look at do we have primary containment do we have secondary containment containment are this good enough or not and then these scorecards when they are filled in are reviewed by the environment agency and the HSA and then you can have a plan if you are deficient in some areas to improve it unless you measure it you can&#39;t improve it that&#39;s the universal truth and here&#39;s pillar number six so we have secondary internship containment serious 764 which I mentioned below the figure is a very good guidance it&#39;s freely available on the website so please type in Syria 764 guidance and it will give you a link to download this guidance it&#39;s very comprehensive and it&#39;s it&#39;s excellent it is really good practice I would say so some of the terms that I&#39;m using secondary containment so what that means is you have a tank for example the tank here and if it was to lose its contents for whatever reason maybe airplane strike or something ridiculous or maybe a while that&#39;s a sheared off because of Aging lack of Maintenance or poor design then are the contents of this tank going to go all over and pollute nearby reverse watercourses or are they going to be contained in a Bund so this bond is a secondary containment so your primary containment is the vessel itself secondary containment is the bond and say for example the bond is to be designed to Syria guidelines which say 110 percent of the largest tank in that or could be 125 percent of the largest tank in a group if compound is not able to contain it then it can overflow go through the drains into the water courses so in in such cases what you can also have is so this is like a backup to a backup to a backup you can have crochet containment so the sites could be designed that old drains speed to Interceptor and anything going from the Interceptor or anything outside the Interceptor could be captured on a low-lying lagoon I understand that it&#39;s not possible for this sort of containment to be built on smaller sites but for the larger size and proportionate to the loss of containment consequences whether it&#39;s toxic pollution or fire or explosion if you run a hazardous site then you must provide this or measure yourself and this gives an indication of how good you are at your process Safety Management tertiary containment is container for product which is over top now there are other scenarios so for example there is a fire in this band is this tank walk figure one there&#39;s a fire and it&#39;s been cooled down by firefighters from a safe distance so you got hydrocarbon releasing that one and you&#39;ve got water coming over so what&#39;s going to happen is the wind is gonna even though it&#39;s designed to 110 of the capacity it&#39;s going to run over and running over hydrocarbons normally are lighter than water so they will come over and they&#39;ll go to wherever they will go and with the fire there&#39;ll be like a running fire pool going all around the side There&#39;s a Nightmare scenario so again having these sort of arrangements and serious 764 will guide you to more more help detailed help detailed technical help my pillar number seven is internal emergency plants so in the UK we have the first two aspects to internal emergency plant which is major accident prevention policy so this is a commitment from the most senior uh levels of your company that you will take measures to prevent major accident so major accident is different to a normal accident I won&#39;t call an accident normal but uh just to be clear major accident is multiple fatalities severe fire toxic cloud smoke going over public areas Etc the second tool that&#39;s used in internal emergency plants and there is very good UK guidance although it&#39;s applicable to UK and the parent Wars and services applicable to all over Europe there&#39;s nothing preventing you from looking at the guidance the guidance is coma approved code of practice l111 I shall be providing links to those for you for your use later on so there&#39;s something called prz so piz stands for public information zone so when our competent Authority receives safety report from us as an operator to actually review it they do predictive calculations of a fire event so say we were to have a jet file a pool fire how far the thermal radiation will be going and who will it harm So based on that they would establish public information Zone so then there&#39;s a legal Duty on us as an operator to write to the public who might be affected by whatever happens on our event and this is very important because if you refer to some of the chemical safety board incident videos people in the neighborhood really didn&#39;t know what was going off in the factory they thought it&#39;s just a normal Factory but when something went wrong there it actually affected the locality around them the sites the another Point within internal emergency plans is exercises invite your local fire brigade who are usually the First Responders to come on your site have a look at what you have and do some sort of tabletop exercises or even on-site exercises with them to understand how they would respond and what are the things that would make their life easy an example of this could be if you have fire water mains on your site which you want to use the fire we get to use when they are on site because they might not have enough water in their tankers is to make sure that your host fittings match what&#39;s on your side so they can very quickly without delay connect to that and use your fire water emergency procedures once they are written should be reviewed and every time you review it or do an exercise you should make changes if required my pillar 8 is external emergency plants so again this is specific to the UK you might have your own regulations do check them when you start talking about process safety external emergency plants actually the responsibility for developing this lies with the local Authority and it has input and consultation with all emergency responders So within the UK the fire brigade the police the ambulance the public health England the health and safety executive environment agency highways Authority Water Authority and so on and also Community groups they all are consulted so what this means is we as operators give scenarios what could go wrong realistically not be ridiculous but realistically we give the scenarios to the local Authority and the local authorism when consults all these statutory consultants and then works out a plan on how they would risk what is their role what is their responsibility and their legal responsibility within the UK under the coma regulations that I keep on mentioning it&#39;s it&#39;s a little exercise for an operator they must do one every three years so every three years there will be an external emergency plan as an example and on one of our sites we are 110 people and they have different roles so the some are players so these people are not aware of what the scenario is until the day of the exercise then you have umpires who can provide information should the agency ask so for example if a fire brigade asks me where do I turn off Electric Supply to this area which is affected then umpire is a knowledgeable person with the site knowledge who tells them yeah you go to this place and that that&#39;s why you can safely turn it off and so on they have observers observers are neutral people they also have people follow the plan what were the improvements required what&#39;s the communication okay what did go wrong and what did go well so at the conclusion there&#39;s like a hot deep riff for 15 minutes everyone then chips in with their uh information and say yeah that went well we could improve on this and then there is a formal called debrief this is all part of the regulations under control of major accident hazards and this is our pillar eight the aim of this exercise is to validate the plan and completely improve it so the moment you think you go to a perfect plan that&#39;s the moment the downfall begins next I mentioned the process safety performance indicators and again there are very good guidance documents from the center for chemical process safety in America our own HSC has HSC 254 which gives you a full guidance in Crystal Clear language without technical jargon or how do you go about identifying and setting up processivity performance indicators so these are the indicators if you go back to the triangle if you refer to the triangle which I showed you earlier on these are the ones which actually will indicate to Senior Management fought my risk controls are doing are this effective are there any issues with my process safety controls my risk control systems and this could be two types it could be lagging which means something&#39;s gone wrong and you&#39;re going to learn from it or it will be leading and it&#39;s important to understand you can&#39;t just have leading indicators you must also learn from lagging indicators if you don&#39;t learn from your learning industry your process safety incidents as I call them then you will never get a true picture so typically risk control systems are operator competence so again one of my first management first pillar of compliance Safety Management System operational procedures do have procedures how do you train your Cooperators against these procedures are these procedures audited do what you do you do what you say you would do or two people develop their own systems of work they&#39;re little shortcuts which might be it might be good for making the work go faster or completing a job with less hassle but might not be correct process safety procedures we have seen examples of Joe living unattended draining of the tank that&#39;s a typical one procedure might say you will stand by that tank until you drain water and not go away the moment a moment&#39;s hesitation could lead to incidents so as I said the process safety indicators could be proactive which is good practice such as plan priority maintenance so that&#39;s very easy to set for you isn&#39;t it if you have planned period maintenance system especially if it&#39;s computer based you know for say for the month of April that&#39;s just gone by you had 30 plan priority maintenance tasks and after the month has gone you look at that and you say okay I managed to complete 20 of the 30. my target was 25 as a minimum so you know that I&#39;m falling behind with my figurative maintenance so that again is an indicator of danger you are not maintaining your plant you&#39;re not maintaining your plant integrity and that can lead to loss of containment so again some homework question for you to think about can you think of what else would be a good process safety indicator last but not the least as I said in one of my safety triangles the core of good process safety is leadership leadership by saying leadership I don&#39;t meet managers I mean the actual senior leaders of the company the board members the executive members of the company Okay so they need to be fully aware of what process safety is how process safety is managed and if there are any breaches of process safety vote is being done about it how do you continuously improve your process safety o and m means operations and maintenance team they pay play a key role and there&#39;s an eternal fight between operations and maintenance and most companies that I know of yours might be an exception so my apologies but most companies operations take precedent or maintenance a maintenance person says you are due for preventing maintenance I need that piece of Kit to refurbish check inspect and reinstate and operations no too busy need to provide the customer with the goods go away that is not the type of dialogue that leads to good process safety leadership so the serial relationship teams if the board members actually go to the site and talk to the people and talk to the operators what are the process safety issues so that search two purposes one is it becomes a two-way conversation and also it raises the awareness of the process safety operators the plant operators who can then relate their tasks to the key process safety failures or Consequences and and consequently be more efficient be more aware to summarize process safety is different compared to occupational safety process safety relates to safe operation of the plant to minimize the potential for fire explosion or environmental contamination and remember all three could happen at the same time process Safety Management involves a lot of different aspects where competency of operators understanding of control measures risk control measures understanding what to do in abnormal process conditions safety critical maintenance are some of the key issues they must be managed by all employees and management now one of the things I would like to mention and maybe um preempting myself is this is a tester session where I&#39;ve just flown through each every topic depending on the feedback we would like to take this further and then have individual sessions on each pillar of compliance so please when you give us feedback do tell us if you&#39;d like some more of the same there&#39;s a video which will try and sort our technical issues with but basically this video is this poem and it&#39;s quite a powerful poem it&#39;s a poem by Don Muriel after an actual incident and it goes I could have saved a life that day but I chose to look the other way it wasn&#39;t that I didn&#39;t care I had the time I was there but I didn&#39;t want to seem a fool or argue over a safety rule I knew he&#39;d done the job before and if I spoke he might get oh the chances didn&#39;t seem that bad I&#39;d done the same I&#39;d taken some chances he knew I had so I shook my head and walked on by he knew the risks as well as I he took the chance I closed an eye and with that act I let him die I could have saved life the day but I chose to look the other way now every time I see his wife I know I should have saved his life that guilt is something I must bear but it isn&#39;t something you need to share if you see a risk that others take that puts their health or life at stake the question asked or thing you say could help them live another day if you see a risk and walk away then I hope never have to say I could have saved a life that day but I chose to look the other way thank you for your time over to Simon okay should I thank you very much for that um I&#39;ve got a number of questions here some have received directly um from the people there so I want to read through them at the time we&#39;ve got left and obviously any that we don&#39;t get the time to go through we&#39;ll we&#39;ll make sure we answer in the in the in what is then posted online so so the first one is at the top of the list I think the one that&#39;s coming most recently yeah the uh the delicate apologize if you if you mentioned this earlier but which of the PSM standards are more widely used in the UK in the UK we tend to use the energy Institute of process safety framework okay and there is a lot of guidance on the HSE website under coma regulations uh which then mentions different standards okay we obviously don&#39;t use the OSHA one but yeah but they&#39;re very similar okay the elements are very similar osm has 11 different so 12 different elements but we covered some of the elements within one of our pillars okay okay thank you specialist the next one and it touches on one of those it&#39;s one of these subjects that when I hear the two words put together in the same sentence I get the hairs on the back of my next stand up change management Yeah you mentioned that earlier um about how the importance of it and how not many people do it right and I I absolutely agree with you on that one is there anything certainly in the process safety World any guidance on that that the delegates could have a look at even if they&#39;re not in the process of the world that actually maybe there&#39;s some principles there that they could be looking at tying into their own system yes certainly I think most uh most regulator sites and I can mention the HSC has got uh good guidance on them and there&#39;s also a very good book by the American chemicals societies ccps guidance for process safety yeah Center for chemical process safety that&#39;s specifically on Monument of change okay it&#39;s a very good guidance and can be used you might have to download or purchase it okay again the safe work Australia Canadian occupational and process safety there&#39;s a lot of guidance available and the thing to do is not to make it more complicated so that people find it difficult to follow what you should do is keep it simple stupid as they say yes I like saying this cliches because they&#39;re great oh he said stupid you&#39;re talking directly to me then but okay no no um the next the next one you talked about maintenance schedules yeah and obviously the use of them underneath them in process safety and I&#39;m I&#39;m kind of adding my thoughts into it here but I&#39;m guessing that the building of your maintenance system you&#39;re probably going to tie that into the hazards that you do to identify the critical elements of your plan to help prioritize yeah is that right because you embellish on that a bit more your your own approach to maintenance schedules and how you would build them for us we first thing we&#39;ve done is we&#39;ve taken the human element of guesswork out by having a structured specific software and there&#39;s lots of software available from different sources and what plant previously maintenance does is it first of all it access your asset resistor you know exactly what you have and then you build in routines into your maintenance system the software allows you to put in procedures so and this procedure should be taken from the design and operation guidance which is supplied with your equipment so for example if you have a pressure vessel the pressure vessel then will say this is my design pressure I should be tested every three years using this standard method so there is no variation there&#39;s no guesswork so that is the approach I would take for preventive maintenance regging so it&#39;s identify your assets put them electronically and then Institute checks now doing more of maintenance is not necessarily good it should be risk based and again on the HSE website if you Google search you will find risk-based inspection and there&#39;s a lot of information fortunately we now live in an age where information is not restricted to paper copies everything is there yeah Google tells us and I guess being based with space that&#39;s where your hazard comes in and that it&#39;s going to identify and properly prioritize yeah that&#39;s it fantastic uh we&#39;ve got we&#39;ve got another question come in um just any guidance on the is there any guidance on the approach to develop and introduce PSN in a company where this would be a New Concept Yes Energy Institute pressure safety framework it&#39;s a very good document to refer to and I shall provide a link to that okay and some of the Publications within those are chargeable but most of it is sort of freely available to public within this they&#39;ve taken each element of process safety and given more detailed guidance so you have the oral framework and then you can go into each element one such example is safety critical identifying your safety critical equipment and then it tells you what to do about it once you identified yeah okay fantastic um another thing that you and you mentioned you mentioned this and it&#39;s obviously quite a hot topic for us in the offshore world with them emergency plans and the testing of emergency plans obviously in the offshore world and the Marine World that&#39;s something that that we&#39;re required to do and required to test and I&#39;m just wandering from a personal perspective what how that&#39;s what that looks like in on the in the onshore world and how often you have to do it is that driven by external factors or is that something that you determine for yourself or yeah the external emergency plants are stretched to a requirement every three years but internal emergency plan is left to the companies on devices so you look at your hazard and see uh have you got a sense of disquiet about it then you do it more often okay what you also do is it should be proportionate to the hazards you hold for our sites which are just basic storage and transfer of fuel it&#39;s different from a say a pharmaceutical site which holds highly toxic chemicals and it mediates sure for them the internal emergency plants are are really critical because the first effect would be on the people nearby if you take Bhopal tragedy for example there the release of methyl isocyanate killed so many people and it went offside as well over there for them doing those scenarios even if it&#39;s just a couple of hours you just grab people at random and say I&#39;ve just got this scenario I&#39;ve lost this toxic chemical what&#39;s the thing you&#39;re going to do just very simple and that should be good and then for further guidance again there is specific guidance by the HSE on emergency plants okay I shall put in reference for that right brilliant thank you another couple of questions come in um next on what defines safety critical equipment under coma under that if that&#39;s an equipment the failure is a one of your major accident scenarios that&#39;s safety critical equivalent so take for example a very simple approach would be if you have bulk tanks and there&#39;s a level gauge on it that&#39;s this safety critical because all your responses your last layer of protection when the level gauge if that level gauge fails you are likely to have an overfill scenario that might lead to if it&#39;s a toxic or very highly flammable liquid of our scenario okay so that would be so if you take the classic bunsfield example the failure of the level switch led to the Fine explosion we were very fortunate that no one was killed had it happen not on a Sunday morning early in the morning had it happened during peak time there were thousands of residents and offices nearby and you&#39;ve seen the devastation just look a monthly and tells you so that is an example of safety critical equipment great thank you Josh uh the next one what models or tools have you seen that help to summarize the vast amount of data on process safety health status to Senior Management whose time is precious that helps them understand where to allocate the resources I guess that&#39;s a great question isn&#39;t it that um no we we are safe professionals we love to talk about we love to have lots of data don&#39;t we in spreadsheets and charts but obviously the people that we&#39;re presenting that to they have a very short attention span occasionally in a very short amount of time to consider it so what tools or what or tips would you give for that that&#39;s pillar nine process safety performance indicators and HSC 254 is a Bible I really like that publication because it lays it out right from beginning about what is about to the final summary now there are companies for example uh Scottish Power they have got a very elaborate dspi tool which is software and it&#39;s wonderful and it throws a lot of attention to you but there&#39;s nothing stopping you a medium or a small size company from developing a spreadsheet which then month on month is reviewed at the board meetings it will only take say 15 minutes and it it just gives you a red green or blue status so sorry red green and yellow status yeah yeah so bread means the trend is downwards what so that then flags up the senior Management&#39;s attention why is just as a classic example why is the pipeline inspection falling behind it&#39;s so critical to maintain this pipeline which contains a high pressure toxic corrosive fluid so that is a key initiator of a major accident on the side so why are we not doing that and that&#39;s the way to get grab board&#39;s attention color coding keep it simple and keep it focused and the other thing which many companies do go down at a tangent with is process safety performance indicator maximum should be six to eight in a very complex refined business or offshore business such as yours I understand appreciate that you could have lots of key hazards and key indicators so the one way to do would be to rotate look at say you choose first six look at that over three months and you see there is no difference discard them start again with different ones and that is the way you can break it down and keep it simple otherwise yeah process safety performance indicator report could be 20 pages long and node yeah looking at it sure except for the person who produced um really good question from Rajesh um any other are there any recognized training courses or diplomas as such on PSN oh yes if you are based in the UK there&#39;s a gold standard process safety awareness course and it&#39;s provided by cogent skills okay and there are different levels there is process safety for leadership and I&#39;ve done one of those and this is very good so code and skills are a provider of training but they don&#39;t actually do the training they have quite a number of certified training companies and training providers so that is something you could look at yeah and there are process safety for operators there&#39;s also a train the trainer course so for a company with say number of sites it&#39;s not practical to take everyone out so what you do is you you take usually people from Assurance or maintenance stuff you train them to deliver the process safety for operators training and I also understand that nibosh is working with iOS yeah to develop a course on processing okay okay rejections followed that by saying I think I&#39;m guessing he&#39;s based in the UAE in the United States [Laughter] but yes there are courses which again U.S websites Center for chemical process safety can also provide correspondent courses okay and you can be certified okay fantastic thank you um going on to I think the final question we&#39;ve got on here again going back to the one we were talking about indicators um questions simply being more leading or lagging indicators so it should be a proportionate mix for both you can&#39;t just rely on leading and you can&#39;t just be on a leg if you&#39;re relying on legging you having too many incidents I would not Advocate that one so it should be a good mix of both and again what I would say to you is if you had a process safety incident and the process safety incidents I also live behind in the American Standard API 570 there is a tier one which is a major major one there&#39;s a tier two and there&#39;s a tier three so tier three is minor so you you could sort of monitor these sort of lagging indicators and comparing it and saying okay we had three tier ones then there&#39;s something definitely wrong or we have had 20 tier threes but no tier twos or no tier ones Ah that&#39;s good we are having minor as fact of life that loss of content will happen but if you spill one liter of a non-toxic non-hazardous liquid that&#39;s different to hundred thousand liters going down the river absolutely absolutely fantastic thank you I think that&#39;s all the questions we&#39;ve got on things so you you can you can sit back in your chair now I think I can only thank you from a personal level collection is something that I I came into this not as interested I think as all the other delegates or something not something I considered myself to be particularly strong in so you&#39;ve given me a great Insight that wasn&#39;t personal level as much and also obviously as a representative of the offshore group here today genuinely appreciate you offering that to our members as well as your own I think it&#39;s been a fantastic insight into what is obviously a very complicated and but also you know but like you we were talking earlier but something that a lot of us do without even realizing it&#39;s probably process safe that&#39;s right I generally appreciate your your input on that so thank you very much indeed just a few things left to say from that from a housekeeping perspective I&#39;m led to believe by Ben my colleague to my left that&#39;s obviously the presentation will be available towards the end of the week hopefully by Friday at the latest it&#39;ll be available to you also and that&#39;ll be available both On the Hazardous Industries and the offshore group internet pages so please keep an eye out for that just a couple of other things to say before we bring this to a close um this is as shalesh mentioned this is the first of the seminars we&#39;ve done together we&#39;re very hopeful of doing some more ones so please keep an eye on connect please keep an eye on on our mutual event Pages just for the next ones that are announced as and when they&#39;re arranged um the Hazardous Industries group webpage I believe is being updated as we speak with their events page in particular so please do keep an eye out for their events I know they&#39;re planning currently and from the offshore with respect of our next event is on Monday coming which is the 15th and that&#39;s back in Aberdeen where we&#39;re doing one on the life of a safety rep obviously as our offshore members on the line will know that it&#39;s been a very challenging time for the offshore industry so we get the Insight of two representatives from Step change and they&#39;re G18 safety reps committee to come and talk about what it&#39;s been like for the last couple of years under very challenging conditions so we have Shane and Dave from the G18 come along to do that so obviously all are welcome so if you&#39;re in if you&#39;re in Aberdeen please do come along and say hello to us I will be there myself and look forward to seeing you all there and just to say also that the offshore group annual conference we&#39;ve now got a confirmation of the date it&#39;s going to be this it&#39;s going to be in October the 19th of October it&#39;s going to be at the Discovery Museum in Dundee and please do keep an eye out for it we&#39;ll be posting some details on that very soon we&#39;ve already got confirmations from a number of speakers including representatives from the HSE and the hsl so please do keep an eye out for that and you&#39;ll see more Communications over the coming weeks all that&#39;s left for me to say is thank you to everybody for for taking the time to dial in today thank you for everybody for raising the questions that you have thank you to shirlesh again for the effort he&#39;s put into the presentation he&#39;s done today and to Ben and iosh for facilitating this for us and we look forward to seeing you soon thank you very much

Transcript for:Offshore Group Webinar Process Safety Insights

Transcript for:
Offshore Group Webinar Process Safety Insights