Download - PSM Auditing (Presentation)
Process Safety ManagementProcess Safety ManagementIntegrating Process Safety into the Santos EHS
Management System2008 National Conference on Major Hazard Facilities
March 2008
Andrew Antony
Manager EHS & Sustainability
2.
4 key stages
• Establishing the right platform
• Defining new standards
• Integrating process safety
• Auditing and monitoring performance
Over the past 5 years Santos has been establishing a process safety management system….
Process Safety ManagementProcess Safety Management
…within a framework that manages environment, health and safety in a consistent manner across the company
3.
2005 2006 2007
Whole of Plant Risk Assessments
Benchmarking
Asset Integrity Management System
PSM standards
Training
Audit program
Process Hazard Analysis
Appointment Lloyds Register
Process safety capability has been improving over time…
…which was formalised through a revision to EHSMS
Santos Process Safety JourneySantos Process Safety Journey
20082002-2004
Moomba Integrity Review
Operations Excellence Forum Established
Procedures Upgrade Appointment
PSM leader & Principal Engineer
4.
A simple definition….A simple definition….
•PSM is used to manage major incident risks
“The application of management systems for the identification, understanding, and control of process
hazards to prevent process related injuries and incidents.”
(CCPS)
5.
4 key stages
• Establishing the right platform
• Defining new standards
• Integrating process safety
• Auditing and monitoring performance
Process Safety ManagementProcess Safety Management
6.
• Safety
• Health
• Environment
• Cultural Heritage
• Greenhouse
• Sustainability
• Security
Environment, Health & SafetyEnvironment, Health & SafetySantos has an integrated approach to manage EHS…
….which provides guidance to all employees & contractors
Procedures
Tools, guides & practices
Management Standards
Policy
EHS Hazard standards
Site Procedures
EHSMS assessment
program
7.
Safety SystemsSafety SystemsImplementation of the EHS management system…..
…has delivered consistent, effective safety approaches across all sites and operations
• Annual improvement across all sites – core systems in place
• Most sites now within the continuous improvement zone
• Moving to audits of effectiveness
• Key focus areas – contractor and risk management
EHSMS Management Standard Assessments
0
20
40
60
80
100
Port Bonython
Ballera Plant
Moomba Plant
Eastern QueeslandMereenie
Production CentralD&PE
Common Processes
Mutineer ExeterFairview
Indonesia USA
EHS & Ops Support
Patricia Baleen(%
)
2003 2004 2005 2006 2007
Continuous Improvement Zone
Baseline in 2006
8.
Personnel SafetyPersonnel SafetyDownward trend in injury rates..…
Total Recordable Case Frequency Rate
0
4
8
12
16
20
98 99 00 01 02 03 04 05 06 07
Santos
Key Programs
• Safety leadership & expectations
• Back to basics skills
• Hand & finger injury program
• Hazard awareness skills
• Health & Wellbeing – Drug & Alcohol testing
• Contractor management
• Driving safety
9.
Personnel safetyPersonnel safety
Personnel Safety Hazards & Behaviours
Fatalities
Recordable Cases
First aid cases
Near Misses
• Personnel Safety • low consequence,
• high frequency
• Personnel Safety • low consequence,
• high frequency
10.
Personnel Safety Hazards & Behaviours
Fatalities
Recordable Cases
First aid cases
Near Misses
Process Safety Hazards & Behaviours
Process Safety Exceptions
Loss of containment
High ImpactIncidents
Safety Safety –– Personnel & ProcessPersonnel & Process
Personnel Safety low consequence,high frequency
Personnel Safety low consequence,high frequency
The focus of process safety is to establish systems, standards and behaviours that will prevent catastrophic events
Process Safetyhigh consequence,
low frequency
Process Safetyhigh consequence,
low frequency
Process safety
Centres around loss of containment of hydrocarbons
Has a potential order of magnitude higher consequence than personnel safety incidents
11.
4 key stages
• Establishing the right platform
• Defining new standards
• Integrating process safety
• Auditing and monitoring performance
Process Safety ManagementProcess Safety Management
12.
New StandardsNew StandardsProcess safety has formalised existing practices and established new standards….
…..to reduce the risk of loss of containment from plant integrity or system failure resulting in serious injuries or plant damage
Procedures
Tools, guides & practices
Management Standards
Policy
EHS Hazard standards
Assessment/ Audit
EHSMS• Design & construction
• Hazard analysis
• Integrity
• Maintenance
• Protection Systems
• Procedures & practices
• Fire risk management
13.
“Layers of protection” concept“Layers of protection” concept
Design Basis
Design & Construction
Pre Start-up Review
Operating Procedures & Safety Practices
Maintenance
Integrity Management
Ignition ControlCritical Protection
Systems
Training andCompetency
Risk Assessments
Management System
Management ofChange
Process HazardAnalysis
SAFEOPERATION
MAJORINCIDENT
14.
New StandardsNew Standards14 new standards…..
• Operations Integrity• Design Basis – Facility and Equipment• Facilities Design and Construction• Pre Start-up EHS Review• Structural Integrity• Mechanical Integrity• Ignition Control• Critical Protection Systems• Operating Procedures and Safe Practices• Maintenance• Fire Risk Management• Decommissioning and Abandonment• Management of Personnel Change
15.
4 key stages
• Establishing the right platform
• Defining new standards
• Integrating process safety
• Auditing and monitoring performance
Process Safety ManagementProcess Safety Management
16.
IntegrationIntegration
Santos Environment Health and Safety Management System
Process Safety Standards
Health and Safety Standards
Environment Standards
Common EHSMS Standards
New Standards
Amended Standards
17.
IntegrationIntegration17 amended standards….• Legal & Other Obligations• EHS Objectives, Targets & Improvement Plans• Responsibility & Accountability• Training & Competency• Consultation and Communication• Document & Records Management• Hazard Identification, Risk Assessment and Control + Hazard Studies• Contractor and Supplier Management• Operated by Others• Management of Change (MOC)• Acquisition and Divestment of Assets• Emergency Preparedness• Monitoring, Management & Reporting• Incident Investigation • Management System Audit and Assessment• Management Review
18.
2005 2006 2007
Whole of Plant Risk Assessments
Benchmarking
Asset Integrity Management System
PSM standards
Training
Audit program
Process Hazard Analysis
Appointment Lloyds Register
Process safety capability has been improving over time…
…which will be formalised through a revision to EHSMS
Santos Process Safety JourneySantos Process Safety Journey
20082002-2004
Moomba Integrity Review
Operations Excellence Forum Established
Procedures Upgrade Appointment
PSM leader & Principal Engineer
EHSMS Revision
19.
4 key stages
• Establishing the right platform
• Defining new standards
• Integrating process safety
• Auditing & Monitoring performance
Process Safety ManagementProcess Safety Management
20.
AuditingAuditing
…..which cover all EHS areas including process safety
Procedures
Tools, guides & practices
Management Standards
Policy
EHS Hazard standards
Assessment/ Audit
EHSMS
Santos is currently changing from assessments to audits…….
• Detailed audit protocols
• Audits typically 2-3 weeks
• Audit teams typically 5-6 people covering…
- Process safety
- Personnel safety & health
- Environment
• Moved away from scoring
• Now identify strengths and non conformances
21.
Loss of containment from plant integrity or system failure resulting in a fatality
Loss of containment from plant integrity or system failure resulting in multiple injuries, hospitalisation or significant plant damage
Loss of containment with potential to cause multiple injuries, hospitalisation or significant plant damage
Minor process safety breach, including exceedence of safe operating envelope for temperature, pressure, corrosion or process chemistry, or a critical operating parameter alarm
Significant process safety breach, involving loss of a layer of protection, including loss of mechanical integrity, failure of shutdown system or critical operating limit exceedence
DESCRIPTORS
Fatality
High Impact
Incident
Loss of Containment
Process Safety Exception
Process Safety Hazards & Behaviours
Reporting Process Safety EventsReporting Process Safety Events
22.
Reporting Process Safety EventsReporting Process Safety Events
Fatality
High Impact
Incident
Loss of Containment
Process Safety Exception
Process Safety Hazards & Behaviours
1. Large release2. Widespread release3. Release requiring site
evacuation
1. Any crack, pinhole, etc, in process piping, leaking or not
2. Ignition sources created (eg, fire, electrical, pyrophric, smoke, etc)
3. Non-compliance to applicable standards (Santos, Australian, International)
4. Permit to work (PTW) breach5. Permit to work (PTW) failure6. Unexpected extreme corrosion7. Valve left open (open port)8. Changes without management
of change (MOC)9. Automatic detection/ protection
system de-activated
1. Permit to work (PTW) breach2. Incorrect tagging3. Inadequate blinds list4. Inadequate critical drawing5. Undesirable and frequent PSV
operation6. Inaccurate or delayed response of
a primary response system7. Changes without management of
change (MOC)8. Non-conformance to standards
23.
Root Case Analysis TrendingRoot Case Analysis Trending
• Hazard & Risk Analysis• Plant Commissioning• Permit to Work• Fire Protection• Management of Change• Operating Procedures• Training & Competency• Plant Design• Inspection & Testing• Maintenance Outcomes
Santos trends process safety events using the following list of controls which appear common across most industry…….
24.
Monthly ReportsMonthly Reports
Process Safety Exceptions by Category - 2007 YTD
22%
14%
20%
11%
12%
9%
5%4% 2%1%
Maintenance Outcomes
Inspection & Testing
Plant Design
Training/Competency
Operating Procedures
Management of Change
Fire Protection
Permit to Work
Commissioning
Hazard & Risk Analysis
Process Safety Exceptions by Site
05
1015202530
Moomba P lantMoomba FieldDullin
ga ri Field
Tirrawarra
FieldBallera Plant
SW Q Field Production
MereenieFairv
iewLytto
n Terminal
Wa llumbilla & SSW ..
Port Bonython
Mutine er E
xe terOyong
Process Safety Exceptions by Category by Month 2007
0
5
10
15
20
25
Jan Feb March April May
Hazard & Risk Analysis
Commissioning
Permit to Work
Fire Protection
Management of Change
Operating Procedures
Training/Competency
Plant Design
Inspection & Testing
Maintenance Outcomes
Process Safety Loss of Containment Incidents by Category 2007
0
1
2
3
4
5
Jan Feb March April May
Hazard & Risk Analysis
Commissioning
Permit to Work
Fire Protection
Management of Change
Operating Procedures
Training/Competency
Plant Design
Inspection & Testing
Maintenance Outcomes
Monthly charts have triggered improved reporting…….
25.
BenefitsBenefits• Process Safety is vital part of the on-going management
of Santos facilities and operations
• Process Safety is now integrated into the EHSMS
• For Santos this will mean
- Specific management of process safety risks
- Establishment of new performance indicators to monitor the ongoing management of PSM risks
- Improve definition of specific process safety responsibilities for staff
• This will result in
- Reduced process safety exceptions
- Reduced loss of containment
- Improved management of process safety issues