adapting and applying process safety management (psm ... · • retail station fires between 1993...
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©Petroliam Nasional Berhad (PETRONAS) 2018 1
© 2018 PETROLIAM NASIONAL BERHAD (PETRONAS)
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Adapting and Applying Process Safety Management (PSM) Concept in Fuel/NGV Retail Stations
Ms Sulo Belawan
CCPS Asia Pacific Regional TSC Meeting, Singapore
2nd Oct 2018
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• US OSHA PSM 1910.119
(a)(1)(ii)(B) atmospheric storage tank (AST) exemption
(a)(2)(i) retail facilities exemption
• API RP 754 Guide to reporting
1.3 Applicability outside the scope of RP 754- k) retail service station
• UK Chemical Act (Control of Major Accident Hazards Involving Dangerous Substances) Regulation 2015
3. (3) these regulations shall not apply to
(c) the transport of dangerous substances and directly related intermediate temporary storage
(d) the transport of dangerous substances in pipelines, including pumping stations, outside establishments
International PSM Regulations and Standards does not cover retail business
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• Major incident involving storage facilities includes:
2005, Buncefield Oil Storage Depot, UK UK HSE later issued requirement for LOPA
2009, Indian Oil Corporation Depot hammer blind valve at transfer line, 11 fatalities
2015, Tianjin Storage Facility, China - 300 buildings destroyed, 173 fatalities
• Retail station fires
Between 1993 and 2004, there were 243 reported incidents of fires breaking out at petrol stations around the world. - Australian Transport Safety Bureau (ATSB)
However, history has proven that process safety risk is inherent in storage and retail facilities dealing with hydrocarbon and chemicals
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Explosion at retail station
PETRONAS is also exposed to process safety risk in its Retail business
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• Safe operation is good for business.
• Maintain brand reputation among our retail stakeholders, customers and other end users
• Keeping up with international standard
In 2015, OSHA issued a letter of interpretation tightening up its definition of
Enforcing Process Safety Management in retail stations is PETRONAS commitment to manage our Process Safety Risk across the supply chain
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2016
2017
2018
2019 & beyond
Identify relevant process safety aspects
Our challenges and journey in implementing PSM in retail business
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Develop business caseConduct PHA Process Safety for NGV
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1. Change management is poorly implemented
2. Technical integrity - Inspection, testing and preventive maintenance program is not comprehensive
3. Inadequate/poor quality of risk assessment
4. Operation discipline inadequate OP / noncompliance to OP
5. Safe System of Works - Inconsistent implementation of Permit To Work system, bypass of Safety Critical Protective Devices, energy isolation
6. Technical competency lack/inadequate knowledge and skill to operate/maintain the assets
Audit and investigation findings provided input in developing a business case for Process Safety enforcement in our retail operations and activities
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Gas supply from GMB@ 260 psig
RegulatorSet @ 200 psig
Metering
Temporary storage tank@ 3600 psig
3-stage compressionInlet : 200 psigOutlet : 3600 psig
Recovery tank
PRVSet @ 400 psig
PLC Panel
Electrical Room
Isolation Valve
Main Valve
Local gauges
Enclosure Ventilation inlet
Start/ESD panel
Compressor Bay FencingEntrance gate
Compressor Bay Fencing
Mai
n S
wit
ch
Bo
ard
Control Room
Gas detector
Priority panelGas detector
Applicable Process Safety Aspects at an NGV Station
MECHANICAL INTEGRITY- Inspection of PRV
PROCESS SAFETY INFORMATION- Pressure Relief
Valve (PRV) Datasheet
- PRV setting
PROCESS SAFETY INFORMATION- P&ID Drawings- Equipment data
sheet
MECHANICAL INTEGRITY- Gas detector testing and calibration
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Public drain
MECHANICAL INTEGRITY
- Inspection of underground tank
MECHANICAL INTEGRITY
- Inspection of fittings and connection
- Inspection of hose conditions
OPERATING PROCEDURE- Loading and
unloading activities
Process Safety Information- P&ID Drawings- Isometric drawings- Safety Data Sheet (SDS)
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Applicable Process Safety Aspects at a Retail Fuel Station
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Our challenges and journey in implementing PSM in retail business
2016
2017
2018
2019 & beyond
Identify relevant process safety aspects
Internal
Develop business case
Process Safety Fundamentals Training
Retail Design Manual
IPFs revalidation
Development of OP
Leading KPIs
Conduct PHA Process Safety for NGV
Asset Integrity Management System
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• Develop retail business specific process safety training pack
• Conduct knowledge level workshop for retail business on the fundamentals of process safety
Process Safety Fundamentals Training
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2016
2017
2018
2019 & beyond
Identify relevant process safety aspects
Our challenges and journey in implementing PSM in retail business
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Develop business case
Technical safety in retail
Group PSM framework and initiatives
Process Safety Fundamentals Training
ITPM for retail business
Retail Design Manual
IPFs revalidation
Development of OP
Leading KPIs
Conduct PHA Process Safety for NGV
Asset Integrity Management System
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Incorporating Inspection, Testing & Preventive Maintenance activities in our retail business
Pipe Misalignment
Worn-out Gasket
Product pipe material deterioration
Cracked Sump Tank
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Our challenges and journey in implementing PSM in retail business
2016
2017
2018
2019 & beyond
Identify relevant process safety aspects
Internal
Develop business case
Technical safety in retail
Group PSM framework and initiatives
Process Safety Fundamentals Training
Sustaining PSM in retail
ITPM for retail business
Retail Design Manual IPFs revalidation
Development of OP
Leading KPIs
Conduct PHA Process Safety for NGVAsset Integrity Management System
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• Specify process safety requirements for retail stations in Group Process Safety Management Framework.
• Include retail business in the Group Process Safety Performance Monitoring and Reporting monitoring.
• Incorporating process safety aspect in retail business auditing scope.
• Reviewing the capability and competency development program
Creating a sustainable effort in managing process safety risk in retail business
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Thank you
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