Offshore Safety Case Training.ppt

One Day Offshore Safety Training Pillai Sreejith

Sreejith

Offshore Training pack

Introduction Offshore Safety Case Training

[email protected] Sreejith

Offshore Training pack

Why this training? • Major accidents do happen around the world, some of them recent, have caused us to ask if they can happen to us – and they certainly can! • We need to ensure they do not happen to us by: • Re-emphasising our safety management system; • Updating our existing Field safety Case; and • Ensuring you all know about it!! Sreejith

Offshore Training pack

What will we learn today? • The difference between occupational/personal and process safety; • What is a major accident; • What is and what is in an offshore Safety Case; • What are the safety barriers / controls/ systems/ Safety Critical Systems (SCE) that prevent major accidents; • The part we all must play in preventing major accidents; and • Test our understanding of what we have learned through Piper Alpha accident. Sreejith

Offshore Training pack

Major Accidents in Oil & Gas Industries • Piper Alpha • 1988 – Major fire and explosion • 167 people died • Caused by PTW failure, PFP flaws and layout issues • Bombay High • 2005 – MSV collision with platform and major fire • 11 People died • Caused by riser damage from MSV impact • Texas City Refinery • 2005 – petroleum distillate overflowed causing explosion & flash fire • 14 People died • Caused by maintenance & process start-up flaws Sreejith

Offshore Training pack

Recent Major Accidents in your offshore Field? Please include details of major accidents (and near-misses) that occurred in your installation/s to tell the participants the need for them to be cautious. Include photographs if you have.

Sreejith

Offshore Training pack

Major Modifications • List down the major modifications (process / marine) that occurred in your offshore installation/s in the past 1 year to tell them that the risk profile has changed: – Examples: • • • • Sreejith

Flare system modifications Addition of a hydrocarbon process equipment Change in mooring system Addition of gas compression facilities Offshore Training pack

What is a safety case? • Operators of offshore installations want to be sure that their operations are safe and do not expose their people or their business to unacceptable levels of risk; • Plant modifications, variations on operating conditions and new ownership mean that the risk picture is changing; and • Regulators and other stakeholders ask you to justify the continuing operation of the installation through safety cases. Sreejith

Offshore Training pack

Corporate HSE Management System Show your HSEMS through a flow chart or a diagram to explain how periodic risk assessment/s are done to update safety case, as part of global sustainability reporting / CSR.

Sreejith

Offshore Training pack

Offshore Safety Case Update project • Key

steps involved:

• Offshore site visit (to assess the safety critical element / barrier performance); • Risk Assessment (using realistic field inputs such as barrier performance to be used in QRA event gates in frequency analysis); and • Safety Case update Sreejith

Offshore Training pack

1 day Training Contents • Difference between Occupational /personal and Process & Marine Safety; • What is a major accident?; • Major Offshore accident case studies; – Piper Alpha – Mumbai High Platform – BP Texas Refinery

• • • •

Potential Major accidents for offshore complex; Offshore Safety Case; Safety Barriers in the offshore complex / installation; and Safety training assessment.

Sreejith

Offshore Training pack

Breaks for the day • 10.30 am: Tea / Coffee Break • 12.30 to 1.30 pm: Lunch break • 3.30 pm: Tea / Coffee Break

Sreejith

Offshore Training pack

Key Message Once the safety systems /barriers fail, there can be major accidents!!! Only you can operate and maintain safety systems without flaws. [email protected] Sreejith

Offshore Training pack

Session Break

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Offshore Training pack

Occupational /Personal, Marine and Process Hazards

[email protected] Sreejith

Offshore Training pack

Learning objectives •To understand major accidents; •To understand the difference between occupational/personal, marine and process hazards; • To understand the ‘Swiss Cheese’ accident causation model and ‘Bow Tie’ barrier concept; • To learn the importance of barriers in controlling major accidents and • To appreciate the need to maintain the safety systems in order to control / mitigate major accidents. Sreejith

Offshore Training pack

Are these terms too obvious and more of a commonsense issue? If so, why are we discussing this? Discussion trigger: BP Texas findings by Mr. Baker panel.

Sreejith

Offshore Training pack

Major Accident (UK HSE SC Regulations,2005 ) • A ‘Major Accident’ defined by UK HSE is: – A fire, explosion or the release of a dangerous substance involving death or serious personal injury to persons on the installation or engaged in an activity or in connection with it; – An event involving major damage to the structure of the installation or plant affixed thereto or any loss in the stability of the installation; – The collision of a helicopter with the installation; – The failure of life support systems for diving operations in connection with the installation; and – Any other event arising from a work activity involving death or serious personal injury to five or more persons on the installation or engaged in an activity in connection with it.

Sreejith

Offshore Training pack

Major Accidents Examples • Deadliest accident so far: 1988 Piper Alpha (167 fatalities); • 2nd deadliest: 1980 Alexander L. Kielland Accommodation rig capsized during a storm (123 fatalities); • 3rd deadliest: 1989 Seacrest drillship capsized during a typhoon (91 fatalities ); and • 9th Deadliest: 2005 Mumbai High Platform fire (22 fatalities). Sreejith

Offshore Training pack

Potential Major Accidents in your Offshore Field • Examples –please customize – – – – – – – – – – – Sreejith

Blowouts Riser & Pipeline releases Process Hydrocarbon Releases – Fire & Explosion Ship Collision Dropped Objects Transportation Accidents Helicopter crash Projectile/Missile impact Structural damage Turret Failure Cargo Tank explosion Offshore Training pack

Occupational Hazards • Personal or Occupational Health and Safety Hazards – Can give rise to incidents or accidents that primarily affect one individual worker for each occurrence

• Personnel injury from: – – – – –

Slips, trips and falls; Electrical shocks; Adverse effects from high noise/heat/dust/fumes; Minor cuts / bruises; and Struck-by objects.

• Generally OH are avoided by wearing PPEs & following procedures Sreejith

Offshore Training pack

Occupational Accidents • Mainly those accidents that can be controlled by the use of PPEs

Sreejith

Offshore Training pack

Source courtesy: Internet

Process Safety & Marine Hazards • Process and Marine Safety Hazards – Can give rise to major accidents that can have catastrophic effects and can result in multiple injuries and fatalities, as well as substantial economic, property and environmental damage

• Examples of these are: – – – – – –

Fires / Explosions Helicopter crash Dropped objects damaging structure or FPSO hull Un-ignited gas releases Ship collisions Riser / pipeline ruptures

Sreejith

Offshore Training pack

Safety Performance OH & PSH • Performance for occupational safety is measured through (eg.) lost time injuries (LTI); and • Performance for process safety is measured process safety equipment performance, hydrocarbon releases, fires, etc. Sreejith

Offshore Training pack

Process Safety Accident

BP Texas City Refinery Fire and Explosion (15 killed, 180 injured) Sreejith

Offshore Training pack

Marine Accident

Ship collision in Japanese waters causing major damage (July 27, 2007) Sreejith

Offshore Training pack

Source courtesy: Internet

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Loss Iceberg

Offshore Training pack

Bow-tie Barrier Concept Events and Circumstances BARRIERS

H A Z A R D

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Harm to people and damage to assets or environment

Major accident

Construction /Engineering activities Maintenance activities Offshore Training pack Operations activities

Source courtesy: Internet

C O N S E Q U E N C E S

Barriers for Potential Major Accidents CONTROL & PREVENTATIVE BARRIERS

THREATS

MAE Major Potential Accidents Blowout (Surface blowouts

Preventative

Emergency response Safe Refuge (Muster Area )

)

Riser Pipeline Releases

Mitigation

Process Hydrocarbon Releases

Instrumentation , i.e. TAHH / LALL / LAHH / PALL / PAHH

Firewater Pumps

Ship Collision Dropped Objects

Detection

Helicopter Crash

Relief System (PSV )

ESD system

Inspections

Control

Firewater Ring main Manual Water Fire Fighting Equipment

ESD Valves

PTW

Navigational Aids

F&G System F&G Detectors

CMMS

Pedestal Cranes

Projectile /missile Impacts

Maintenance

Inert Gas System

Structural Environmental events

Deluge System Wellhead Isolation Blowdown Valves ESD Manual Pull Stations HVAC

Audits

Ignition control

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Cargo tank explosions

Offshore Training pack

Emergency Power (UPS ) Internal Communications & Alarms

Blowdown Valves

Helideck Crash Equipment

ESD Manual Pull Stations

Miscellaneous Safety Equipment

Gaseous Systems

Turret failure

Emergency Lighting

External Communications

Firewalls

/

Escape Routes

Manual Foam Fire Fighting Equipment

Transportation Accidents Miscellaneous Temporary Equipment

CONSEQUENCE

MITIGATIVE BARRIERS

TEMPSC & Life rafts Helicopter Facilities Direct to Sea Equipment

Do you know where these safety barriers are in your installation/s? • Fire walls (are they A or H or J type? What does these alphabets mean?; if there is A 60 fire wall, is this acceptable? Why?) • Blast walls (are blast and fire walls same? How are their locations decided?) • Flame / flash back arrestors • ESD push buttons Sreejith

Offshore Training pack

Safety Barriers Explanation-Example 1 • Ignition Control – Hazardous Area Classification – Use of Ex type equipment (do you know how they are designed? Why can’t they be designed as vapour / gas tight?) – Flash back arrestors, spark arrestors – Static charge discharge control (bonding, when do you install bonding? Why is this done?) – Lightning control (how do you control these hazards?) – Inert gas system for cargo tanks – Use of inert gas system to dilute hydrocarbon vapours at vents

Sreejith

Offshore Training pack

Safety Barriers Explanation-Example 2 • What are the difference between Passive Fire Protection (PFP) & Active Fire Protection (AFP)? • Examples of PFP? – Fire walls – In tumescent coatings (ESD valves?) – Heat shields on the escape routes?

• Examples of AFP? – Deluge – FM 200 Gaseous Fire Fighting system – Fire & Gas Detection system Sreejith

Offshore Training pack

Fire walls, Blast walls, Heat Shields J 45/ H60, 0.3 bar Blast wall

A 60 Firewall

Blast wall in place Sreejith

Source courtesy: Internetpack sources Offshore Training

Heat Shield

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Offshore Training pack

Source courtesy: Internet

Sreejith Offshore Training pack

EXPLOSION

Audits MOC

Integrity Inspection of PFP firewalls

CFT on Fire Pumps & Valves Testing of foam concentrate MOC

Fire Drills Audits

Audits/Inspection

CFT on ESDV Loop Checks

Mitigation barriers

PASSIVE FIRE PROTECTION

ACTIVE FIRE PROTECTION

EMERGENCY SHUTDOWN

FIRE & GAS DETECTION

Audits MOC/ECR

Loop Checks Detector Calibrations

Loop checks for BD Audits/Inspection CFIs on Relief Valves

HAC Static Electric Audits

Maintenance Checks/test Calibration Loop Checks Simulation Audits MOC/ECR

Performance Indicators (Leading & lagging)

Prevention barriers

BLOWDOWN & RELIEF SYSTEM

IGNITION CONTROL

PROCESS INSTRUMENTATION

Hydro Carbon Releases

Explosion / Fire Swiss Cheese Model

Discuss • For major accident control, which side of the bow tie should be strong? Left (prevention) or the right side (mitigation) ? Why? Major Accident

Discussion trigger: Can a gas explosion be effectively mitigated prevented with water deluge? Sreejith

Offshore Training pack

Learning • • • • •

Major accidents; Potential major accidents at your offshore installation; Difference between personal / occupational, marine and process accidents; Swiss Cheese & Bow Tie safety concepts; and Importance of safety barriers in controlling major accidents.

[email protected] Sreejith

Offshore Training pack

Session Break

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Offshore Training pack

Major Accidents in your Offshore Field

[email protected] Sreejith

Offshore Training pack

Learning Objectives • To learn about the major accidents that occurred in your offshore complex to understand ‘What went wrong?”; and • To think about the potential barrier failures that might exist at offshore installations which could lead to potential major accidents. Sreejith

Offshore Training pack

Offshore Complex • Show the field diagram • Show the platforms / FPSOs and the interconnecting pipelines • Include the major additions / modifications to highlight to the participants that the installation has changed over the years Sreejith

Offshore Training pack

Platform Accident Details • Show the accident & near-miss trends (bar chart) and discuss cause breakdown (pie-chart) • A graph that shows no particular trend (upward or downward) could mean: – The HSE is not under control; – The HSE performance / accident data collection / analysis is not proper; – No one knows what will be the future HSE performance is! Sreejith

Offshore Training pack

Major Accidents •

•

•

Identify major accidents, hi-potential incidents, near-misses;

Discuss each of the major cases from the detail reports to explain: Causes – Consequences – Risk reduction recommendations – Implementation status – Any similar accidents occurred? –

If there are any photos of these accidents, show them.

Sreejith

Offshore Training pack

Causes Examples • Inadequate planning / organization; • Flaws in PTW procedures; • Written job procedure did not anticipate contributing factors; • Failure to follow known job procedure (s); • Inadequate training; • Supervisor failure to identify unsafe condition; and • Failure to communicate.

Sreejith

Offshore Training pack

Learning • If no concrete action is taken to rectify the cause of the incident permanently, it might lead to an accident next time round – History has proven this; • Accidents could happen even with safety barriers in place; • Personnel play an extremely important role in promoting safety – competency, experience and knowledge is important; and • We need to ensure that the safety barriers are maintained so as to control / mitigate accidents. Sreejith

Offshore Training pack [email protected]

Session Break

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Offshore Training pack

Potential Major Accident Events at Your Offshore Complex

In this presentation, the typical potential major accidents for FPSO / platform are included. This will require customisation in line with the field QRA results.

Sreejith

Offshore Training pack pillai_sreejith@hotmail. com

Learning Objectives • To learn about the potential major accidents that can occur in offshore field and to understand the consequences; • To be aware of the major risk contributors at offshore installations; and • To be aware of the risk levels for various personnel at your offshore field.

Sreejith

Offshore Training pack

Potential Major Accidents 1 Examples 1. Surface Blowout

4. Ship collisions

2. Riser / Pipeline Releases 5. Dropped Objects

3. Process HC Releases –Fires / Explosions 6. Transportation Accidents Sreejith

Offshore Training pack Source courtesy:

Internet

Potential Major Accidents 2 Examples 7. Helicopter crash 10. Turret Failure

8. Projectile / Missile impact 11. Cargo Tank Explosion

9. Structural damage

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Offshore Training pack Source courtesy:

Internet

Risk Terminology • Individual Risk (IR) Individual Risk Per Annum is the frequency with which an individual may be expected to sustain fatal harm due to exposure to specific hazards in a year

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Internet

ALARP Triangle

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Offshore Training pack Source courtesy:

Internet

What does risk mean?

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Offshore Training pack Source courtesy:

Internet

• • • • • • •

Essential data used in Quantitative Risk Assessment (QRA)

Manning distribution Transportation details Heat & Material Balance diagram P&IDs PFDs General Arrangement / Layouts Design basis and safety philosophies

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Offshore Training pack

Offshore Installation

Areas • Show the areas considered in the QRA • Explain the manning distribution of various personnel categories in the areas • Tell them the risks calculated is rather realistic since we have considered more facts

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Offshore Training pack

Fires and Explosions • Pool Fire • Jet fire • Vapour Cloud Explosion • Flash Fire Sreejith Offshore Training packof each type of fires Explain the causes and consequences including their impairment potential

Impairment • Discuss impingement and impairment from pool and jet fires • Pool fire impingement on steel structures: – 10 minutes

• Jet fire impingement on steel structures: – 5 minutes

Sreejith

Courtesy: CMPT QRA Offshore Training pack Guidelines

Risk assessment Flow Chart HAZID: Identify potential hazards

Sectionalisation: Review PFDs, UFDs & P&IDs to separate the process and utility system to various isolatable sections.

Causal Analysis: Identify hazardous events associated with accidents

Frequency Analysis and Event Tree Analysis: Frequency of each accidental event (top event) and branch probabilities are assigned to event tree and outcome event frequency are estimated.

Consequence Modelling: Using the software. The physical effects and damages for each outcome event are estimated

Impact Assessment: Analyse the fire and explosion impact to structures and equipment.

•Risk Assessment Fatality Estimation: Determine the risk to personnel from each outcome event. •Risk Summation and Risk Ranking: Sum the risks to individual from each outcome events for hydrocarbon and non-hydrocarbon hazards and identify the dominant risk contributors. Risk Assessment: Compare the risk levels against Individual Risk Acceptability Criteria to determine whether additional measures are necessary to reduce risks to ALARP.

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Offshore Training pack

Risk reducing measures: Apply enhanced or additional control measures and mitigation measures.

Potential Major Accidents Offshore Field

Sreejith

Offshore Training pack

MAE 1 Surface Blowout Causes: Failure of choke valve Failure of X’Mas tree / DHSV / SCSSV Presence of ignition sources

Consequences: Jet Fire Major asset damage Multiple fatalities / injuries

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Offshore Training pack Source courtesy:

Internet

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Offshore Training pack

Source courtesy: Internet

Subsea blow out Sreejith

Offshore Training pack Source courtesy:

Internet

Fire Contours • Show the jet, pool fire contours superimposed on the offshore installation layout drawing to show them the potential effects.

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Offshore Training pack

MAE 5 Dropped Objects Causes: Failure of lifting equipment (overload / damaged lifting equipment) Failure of crane equipment (overload, etc.) Lifting without following procedures / controls Consequences: Asset damage (hull, equipment, platform, etc.) Multiple fatalities / injuries

Sreejith

Offshore Training pack

Source courtesy: Internet

Transportation Accidents Helicopter, boat, personnel transfers

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Offshore Training pack

Risks from transportation

ANOA FIELD

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Offshore Training pack

Source courtesy: Internet

MAE 6 Transportation Accidents Causes: Mechanical failure of boats / helicopter/ flights Extraneous weather conditions Material defects of personal transfer baskets or associated lifting tackles

Consequences: Asset damage (hull, equipment, platform, etc.) Multiple fatalities / injuries

Sreejith

Offshore Training pack

Source courtesy: Internet

Personnel Basket Transfers

•Protection from side & vertical impacts? •Personnel falling from height due to giddiness, loss of grip, high wind, loss of balance, etc. Sreejith

Offshore Training pack

Is there an option?

MAE 7 Helicopter Crash Causes: Failure of helicopter (engine failure / extreme weather) Failure of communication equipment Fire / explosion in FPSO / Platform Pilot error Consequences: Fire Major asset / helicopter damage Multiple fatalities / injuries

There are hardly any known occurrences of Helicopter crashing into FPSO or platform Sreejith

Offshore Training pack

Source courtesy: Internet

Sreejith

Offshore Training pack

Source courtesy: Internet

MAE 8 Projectiles / Missiles Causes: Failure of equipment due to overpressure Inadequate design Missiles / projectiles from gas turbines and FPSO steam turbines

Consequences: Asset damage (hull, equipment, etc.) Multiple fatalities / injuries

Sreejith

Offshore Training pack

Source courtesy: Internet

Sreejith

Offshore Training pack

Source courtesy: Internet

MAE 9 Structural Events Causes: Structural failures due to extreme weather Corrosion Inadequate design Crane boom collision

Consequences: Asset damage Multiple fatalities / injuries

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Offshore Training pack

Source courtesy: Internet

MAE 9 Structural Events

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Offshore Training pack

Source courtesy: Internet

MAE 9 Structural Events

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Offshore Training pack

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MAE 10 Turret Failure

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Offshore Training pack

Source courtesy: Internet

MAE 11 Cargo Tank Explosion

Sreejith

Offshore Training pack FPSO

Overall Risk for Offshore Complex

•

Explain the Individual Risk (IR) for the various personnel categories;

•

Explain the PLL (Potential Loss Of Life) values for the complex and various personnel categories;

•

Discuss if the IR value is within the ALARP tolerable region;

•

Explain the major risk contributors for the offshore complex;

•

Explain what is base case IR, and ALARP IR cases (sensitivity cases); and

•

Explain what is traffic light system and how is it used to determine Realistic Risk levels?

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What is Traffic Light system? Traffic Light system is used as an assessment tool by UK HSE, NOPSA, etc.

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Offshore Training pack

Traffic lights system and performance of safety systems • Traffic light system was used to assess the performance of safety systems; • The performance of safety systems were determined based on: – Critical maintenance test results; – Accidents / incidents; – Maintenance backlogs; and – Offshore audit findings. How will the TL System used to calculate Offshore Training pack impairment / event frequencies in QRA?

Sreejith

Traffic Light Interpretation Tolerable

Not accepta

ble

Acce ptab le

Partially degraded

Safety Systems Performance Sreejith

Offshore Training pack

Earlier risk IR 1 Risk after Safety System performance Assessment IR 3 Base case risk IR 2

Potential residual risk after improvements IR 4

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Offshore Training pack

Learning • Individual Risk for all offshore personnel are within the acceptable limits; • Understanding potential major accidents for offshore installations (causes and consequences); • Understanding the major risk contributors at offshore field; and • Understanding the personnel risk levels for various categories.

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Offshore Training pack

Session Break

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Offshore Training pack

Offshore Safety Cases

[email protected] Sreejith

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Learning objectives •To understand the objective of Safety Cases; •To understand ‘The UK HSE Offshore Installations (Safety Case) Regulations 2005’; •To understand the typical SC update triggers; and •To know the Typical Safety Case contents.

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Offshore Training pack

Safety Case-Definition “A documented body of evidence that provides a convincing and valid argument that a system is adequately safe for a given application in a given environment”

Safety Case exists for Nuclear, Offshore, Aviation, and Rail industries

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Offshore Training pack

Safety Case Origin (post 1988 Piper Alpha explosion)

“UK Offshore Operators, says Cullen, must adopt this new philosophy on safety, producing a ‘Safety Case'. This includes continuous hazard assessment over the plant's lifetime, fault tree analysis, which looks at all the ways an error could develop, and takes account of ways that 'human factors' contribute to disasters” Sreejith

Offshore Training pack

Safety Case Evolution Timeline

Forthwith: Immediate, at once Lord Cullen recommended that the 4 (FEA, ESSA, EERA,SIGA) be carried out by the offshore operators immediately before the 1992 safety case regulation was released. Sreejith Offshore Training pack

Why Offshore Safety Case? • Operators of offshore installations want to be sure that their operations are safe and do not expose their people or their business to unacceptable levels of risk; • Plant modifications, variations on operating conditions and new ownership mean that the risk picture is changing; and • Regulators and other stakeholders ask you to justify the continuing operation of the installation through safety cases. • Regulatory compliance is essential to your business Sreejith

Offshore Training pack

Safety Case • First SC Regulations came into force in 1992; • Cullen Forthwith studies: – A Fire Risk Analysis; – An assessment of the risk of ingress of smoke or gas into the accommodation; – A review of the ability of emergency systems to withstand severe accident conditions; and – An evacuation, escape and rescue analysis. Sreejith

Offshore Training pack

The UK HSE Offshore Installations (Safety Case) Regulations 2005 •

Key changes introduced by the 2005 Regulations include: -The requirement for duty holders to send an early design notification, instead of a design safety case, to HSE when establishing a new production installation; -Duty holders are required to carry out a thorough and fundamental review of their safety cases at least every five years, or as directed by HSE; -The present requirement to re-submit safety cases every three years has been removed (inspectors will be checking to see that safety cases are being kept up to date through inspection); -New duties require licensees to ensure anyone they appoint as an operator is capable of fulfilling their legal responsibilities for safety; -Combined operations safety cases have been replaced by notifications, which do not need HSE acceptance; and -The Offshore Installations (Safety Representatives and Safety Committees) Regulations have been amended to extend consultation with safety representatives to reviewing and revising a safety case, as well as preparing one.

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Offshore Training pack

Typical Contents of Safety Case Facility description HSE Management system Formal Safety Assessment (FSA) Summary Safety Critical elements and Performance Standards • ALARP Demonstration • Fitness to Operate • • • •

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Offshore Training pack

Safety Case Update Triggers Examples

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Offshore Training pack

Learning • Origin and objectives of Safety Case; • Piper Alpha Accident & Safety Case; • ‘The UK HSE Offshore Installations (Safety Case) Regulations 2005; • Typical SC contents; and • Typical SC update triggers.

Sreejith

Offshore Training pack

Session Break

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Offshore Training pack

Safety Barriers and their Role in Controlling Major accidents

[email protected] Sreejith

Offshore Training pack

Learning objectives •To understand the critical role of safety barriers / safety systems in controlling major accidents using Bow-Tie diagram; •To understand safety barriers on offshore installations; •To appreciate the need to maintain the barriers through maintenance system, inspections, etc.; and •To identify and monitor performance of safety barriers through lead and lag indicators. Sreejith

Offshore Training pack

Bow Tie Diagram

Sreejith

Offshore Training pack Source courtesy:

Internet

Barriers for Potential Major Accidents CONTROL & PREVENTATIVE BARRIERS

THREATS

MITIGATIVE BARRIERS

MAE

Emergency re

Safe Ref (Muster A

Blowout (Surface blowouts )

Preventative

Riser Pipeline Releases Mitigation

Instrumentation , i.e. TAHH / LALL / LAHH / PALL / Inspections PAHH

Process Hydrocarbon Releases

Firewater Pumps

Ship Collision Dropped Objects

Detection

Helicopter Crash

Relief System (PSV )

ESD system Control

Firewater Ring main Manual Water Fire Fighting Equipment

ESD Valves

PTW

Navigational Aids

Pedestal Cranes

Audits

F&G System F&G Detectors

CMMS Tur ret failures Projectile /missile Impacts

Inert Gas System

Ignition control Miscellaneous /

Carg o t ank explos ions Structural Environmental events

Wellhead Isolation Blowdown Valves ESD Manual Pull Stations HVAC

Manual Foam Fire Fighting Equipment

Emerge Power (U

Intern Communica & Alar

Extern Communica

Helideck C Equipm

ESD Manual Pull Stations

Miscellan Safet Equipm

Firewalls

TEMPSC rafts

Gaseous Systems

Offshore Training pack

Emerge Lightin

Blowdown Valves

Transportation Accidents

Temporary Equipment

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Deluge System

Escape R

Helicop Faciliti

Direct to Equipm

UK HSE KP 3 Inspection Results

Sreejith

Offshore Training pack Source courtesy:

Internet

Sreejith

Offshore Training pack Source courtesy:

Internet

What is wrong at present in oil & gas industry? • Unacceptable level of process safety related dangerous occurrences especially in relation to loss of containment incidents; • Major hazard industry measured safety performance using LTIs!! • Critical systems deteriorate over time without warning until they fail catastrophically; and • Audits tend to be too infrequent and workplace inspections focus on personal safety. Sreejith

Offshore Training pack

Process Safety Management System An effective process safety management system measures performance Key performance indicators must include appropriate indicators of process safety performance Sreejith

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Key Performance Indicators set to identify defects in safety systems

Accident Trajectory Lagging indicator

Leading indicator

Lagging indicator

Lagging indicator

Permit-to-work Leading indicator

Inspection & Maintenance Lagging indicator Leading indicator

Staff Competence

System defects

Leading indicator Operational Procedures

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Offshore Training pack Source courtesy:

Internet

Sreejith Offshore Training pack

EXPLOSION

PASSIVE FIRE PROTECTION

ACTIVE FIRE PROTECTION

EMERGENCY SHUTDOWN

FIRE & GAS DETECTION

BLOWDOWN & RELIEF SYSTEM

IGNITION CONTROL

PROCESS INSTRUMENTATION

Hydro Carbon Releases

Audits MOC

Integrity Inspection of PFP firewalls

CFT on Fire Pumps & Valves Testing of foam concentrate MOC

Fire Drills Audits

Audits/Inspection

CFT on ESDV Loop Checks

Audits MOC/ECR

Loop Checks Detector Calibrations

Loop checks for BD Audits/Inspection CFIs on Relief Valves

HAC Static Electric Audits

Maintenance Checks/test Calibration Loop Checks Simulation Audits MOC/ECR

Performance Indicators (Leading & lagging)

PROCESS HYDROCARBON RELEASES/FIRES/EXPLOSIONS Example

Dual Performance Assurance Dual Assurance - leading and lagging indicators measuring performance of each critical element of a Process Safety Management System

Reactive Monitoring Lagging Indicator:

Critical Process Safety Risk Control System

Active Monitoring Leading Indicators: Process or Input Indicators

Outcome Indicator

Sreejith

Offshore Training pack Source courtesy:

Internet

How effective are YOUR safety systems? • Traffic light system was used to assess the performance of safety systems; • Each of the safety systems were assessed based on: – Critical Maintenance Test (CMT) results; – Accidents / incidents; – Maintenance backlogs; and – Audit findings. Sreejith

Offshore Training pack

Traffic Light Interpretation Tolerable

Not accepta

ble

Acce ptab le

Partially degraded

Safety Systems Performance Sreejith

Offshore Training pack

Offshore Audit Findings Examples • H 60 fire walls penetrated to pass pipes and electrical conduits • Fire water deluge not provided for critical hydrocarbon systems / valve clusters • Flame Detectors obstructed with pipework • Hazardous area Classification compromised • Ex equipment maintenance flaws

Sreejith

Offshore Training pack

Safety Barrier Performance CONTROL & PREVENTATIVE BARRIERS

THREATS

MITIGATIVE BARRIERS

MAE

Emergency re

Safe Ref (Muster A

Blowout (Surface blowouts )

Preventative

Riser Pipeline Releases Mitigation

Instrumentation , i.e. TAHH / LALL / LAHH / PALL / Inspections PAHH

Process Hydrocarbon Releases

Firewater Pumps

Ship Collision Dropped Objects

Detection

Helicopter Crash

Relief System (PSV )

ESD system Control

Firewater Ring main Manual Water Fire Fighting Equipment

ESD Valves

PTW

Navigational Aids

Pedestal Cranes

Audits

F&G System F&G Detectors

CMMS Tur ret failures Projectile /missile Impacts

Inert Gas System

Ignition control Miscellaneous /

Carg o t ank explos ions Structural Environmental events

Wellhead Isolation Blowdown Valves ESD Manual Pull Stations HVAC

Manual Foam Fire Fighting Equipment

Emerge Power (U

Intern Communica & Alar

Extern Communica

Helideck C Equipm

ESD Manual Pull Stations

Miscellan Safet Equipm

Firewalls

TEMPSC rafts

Gaseous Systems

Offshore Training pack

Emerge Lightin

Blowdown Valves

Transportation Accidents

Temporary Equipment

Sreejith

Deluge System

Escape R

Helicop Faciliti

Direct to Equipm

Process Safety Management Major Hazard Analysis/Maintenance Loop

Maintenance Management

Major Hazard Analysis

Are The Barriers Being Properly Maintained?

IDENTIFY Barriers; (SCEs)

Performance Indicators Are They Suitable?

Sreejith

Offshore Training pack Source courtesy:

Internet

Learning • Concept of Safety barriers in major accident control; and • Role of offshore personnel in ensuring integrity of safety barriers by monitoring performance indicators; and • Performance of safety systems to control major hazards cannot be monitored using LTIs which calls for a shift in focus.

Sreejith

Offshore Training pack

Key Message Once the safety systems fail, there can be major accidents!!! Only you can operate & maintain safety systems without flaws.

[email protected] Sreejith

Offshore Training pack