experience with developing process safety kpis within scottishpower
DESCRIPTION
Process safety management for power and steam generation Energy Institute, LondonTRANSCRIPT
Experience with developing Process Safety KPIs within ScottishPowerProcess safety management for power and steam generation Energy Institute, London
8th July 2010
Martin Sedgwick – Head of Asset ManagementSteven Stewart – Process Safety Design Authority
AgendaOverview of ScottishPower’s journey implementing PSPIs...
Brief introduction to ScottishPower
Approach To Developing Process Safety Leading and Lagging Indicators
Current Status Of Indicators
Enduring Process Safety Solution
Management / Board Reporting
Process Safety Key Learning Points
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Iberdrola GroupScottishPower part of Iberdrola Group, a worldwide leader in energy…
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Presence in 40 countries worldwide
ScottishPower OverviewScottishPower is a major integrated power company...
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ENERGY RETAIL
5.3m customers
ENERGYNETWORKS3.4m customers
#3 UK distribution
network operator
ENERGYWHOLESALE
~6GW flexible generation
Energy Management
Gas Storage
COMPETITIVEREGULATED
UK
© ScottishPower 2010 – Energy Institute Seminar
Approach To Developing Process Safety Leading and Lagging Indicators
8th July 2010
Longannet Power StationCarbon Capture Pilot Plant
6
Overview Of Approach
Based on HSG254 – recognised as best practice
Tested through benchmarking - HSE and Oil & Gas sector
Common KPIs for all sites, but different targets applied
Incremental approach – trials using prototype dashboard
Buy in and sign off from the top
KPI Lifecycle developed:
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Application Of HSG254...
© ScottishPower 2010 – Energy Institute Seminar
Step 1 - Hazards…
People
Process
Plant
90 GENSIPHazards
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Application Of HSG254...
© ScottishPower 2010 – Energy Institute Seminar
Step 2 – Risk Control Systems…
People
Process
Plant
90 GENSIP Hazards
42 Risk Control Systems
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Risk Control Areas
© ScottishPower 2010 – Energy Institute Seminar
Risk Control Systems Grouped Into 8 “Risk Control Areas”...
Operation & Compliance Audit
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Application Of HSG254...Step 2 – Risk Control Systems…
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People
Process
Plant
90 GENSIP Hazards
42 Risk Control Systems
Application Of HSG254...
© ScottishPower 2010 – Energy Institute Seminar
Step 3 – Define Leading Indicators
People
Process
Plant
90 GENSIP Hazards
42 Risk Control Systems
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100 Leading Indicators
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© ScottishPower 2010 – Energy Institute Seminar
KPI Definition Documents
Provides definition of KPI:
ObjectiveDefinitionData SourceData Aggregation / CalculationTargets
Data Recording Guidelines
Formal sign off by senior managers
Crib sheets used to specify each KPI in detail…
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Application Of HSG254...
© ScottishPower 2010 – Energy Institute Seminar
Step 3 – Define Leading Indicators
People
Process
Plant
90 GENSIP Hazards
42 Risk Control Systems
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100 Leading Indicators
14
Application Of HSG254...
© ScottishPower 2010 – Energy Institute Seminar
Step 4 – Classify Lagging Indicators…
People
Process
Plant
3 Classifications Of Lagging Indicators
90 GENSIP Hazards
42 Risk Control Systems
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100 Leading Indicators
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© ScottishPower 2010 – Energy Institute Seminar
Application Of Latest Thinking
Classification of Process Safety Incidents based on benchmarking with HSE and API guidance:
Major Process Safety Incident:• Equipment damage > £100k • Loss of Production > 24 hours• Injuries / fatalities (RIDDOR)• Major environmental impact
Significant Process Safety Incident: • Equipment damage > £20k but <£100k• Significant release of energy or
hazardous matter• Fire and explosions
Minor Process Safety Incident:• Demand on safety system• Process upset – control loops out of
control, equipment in manual• Breaches of plant limiting conditions
Approach to classification of lagging indicators...
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Application Of HSG254...Step 4 – Classify Lagging Indicators…
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People
Process
Plant
3 Classifications Of Lagging Indicators
90 GENSIP Hazards
42 Risk Control Systems
100 Leading Indicators
Application Of HSG254...
© ScottishPower 2010 – Energy Institute Seminar
Incident Management key to understanding lagging indicators...
People
Process
Plant
3 Classifications Of Lagging Indicators
90 GENSIP Hazards
New Incident
ReportingProcess
42 Risk Control Systems
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100 Leading Indicators
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Incident InvestigationApplication of Swiss Cheese model to drive out lagging indicators...
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Emergen
cy P
repare
dnes
s
Alarm / I
nstru
mentat
ion M
anag
emen
t
Critica
l Sys
tems M
anag
emen
tStaf
f Com
peten
ce
Mainten
ance
Man
agem
ent
Operat
ions M
anag
emen
t
Tech
nical
Risk M
anag
emen
t
Operat
ional
and C
ompli
ance
Aud
its
Hig
h te
mpe
ratu
re s
team
pi
pes
and
oil s
yste
ms
in
clos
e pr
oxim
ityTurbine Pedestal Fire
Strainer drain line restraints failed, pipe
movement
Fire hydrants defects unknown
Resetting governor creates oil hammer Deluge system
manually operated
Deluge valves located in Turbine
Hall, delaying access
Strainer drain line weld defective from
installation
Vacuum Breakers fail, extending run down
time Various oil leaks
Delays in applying Deluge system causes damage to system reducing efficacy
No Turbine/ Major Incident Fire Procedure
No Plant Modification history giving detail of
design rationalDelay as Fire
Brigade procedures
require BA bottle replacement
Strainer east drain line left open pressurising
drain line
Decision to not use the Deluge system for fear of
plant damage and exacerbating fire
Missing persons did not follow evacuation procedure
Local Procedures not well known for first contact with Fire Services
Application Of HSG254...
© ScottishPower 2010 – Energy Institute Seminar
Outcomes documented in PSMS…
People
Process
Plant
3 Classifications Of Lagging Indicators
90 GENSIP Hazards
New Incident
ReportingProcess
100 Leading Indicators
42 Risk Control Systems
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Process Safety DashboardMatrix – shows worst case KPI across all RCAs at each site…
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Process Safety DashboardKPI Details – shows status of individual KPIs…
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Process Safety DashboardTrends show the positive impact that KPIs have had on performance…
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Process Safety DashboardDrill Down – enables the source of issues to identified and tackled…
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Process Safety DashboardSummary Charts – provide view of risk profile…
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Process Safety DashboardMonthly Reports – support Operational Risk Governance meetings…
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Enduring Dashboard SolutionPreview of next generation of software in development...
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Further HSE Guidance
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Three categories of indicators …
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Further HSE Guidance
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Shift Logging …
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Further HSE Guidance
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Alarm Management …
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Further HSE GuidanceAlarm Management …
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Further HSE Guidance
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Reliability Engineering …
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Further HSE GuidanceReliability Engineering …
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Further HSE Guidance
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Maintenance Management …
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Further HSE GuidanceMaintenance Management …
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Further HSE Guidance
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Incident Management …
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Further HSE GuidanceIncident Management …
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Further HSE Guidance
© ScottishPower 2010 – Energy Institute Seminar
Technical Risks …
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Further HSE GuidanceTechnical Risks …
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KPI Dashboard ArchitectureAn enterprise scale solution...
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Ad
Hoc
Ana
lysi
s (B
usin
ess
Obj
ects
)
Scheduling
EXP(Reliability Engineering)
PSR(Technical Risks)
Maximo(CMMS)
Cintellate(Incident Management)
PAS (Alarm Management)
Opralog(Shift Logging)
Dashboard
Process Safety DashboardLeading and lagging KPIs listed separately...
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Process Safety DashboardConcept of Leading and Lagging indicators embedded...
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Process Safety DashboardDonut charts used to report leading and lagging statistics separately...
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Weighted KPIsApplication of risk based weightings to KPIs...
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Top 10 KPI ReportProposed approach to ranking KPIs...
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Operational Control Indicators
Calculate Score Between 0 and 4 For
Each KPI
Apply Offset To Each KPI Based on
Category
+0
+1
+2
Top 10 KPI Reporting
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Operational Control IndicatorsGeneric Indicators
Programme Indicators
0 1 2 3 4 5 6
KPI Weight ApproachEnables individual KPI scores to be aggregated up to RCA level...
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Maintenance Management
Work Prioritisation
Work Identification, Routine Plant Inspections
Work Planning, Scheduling
Work Execution
Personal Risk Assessment
KPI RCA Weighting
Backlog Size In Months 20%
Corrective Maintenance Compliance 10%
Outage Defects Backlog Size In Months 5%
Percentage of WOC With Failure Information 2%
Percentage of WOC With Hours Captured 2%
Percentage of WOC With Log Completed 2%
Percentage of WOC With Re-Work 1%
Percentage of WOC With Risk Assessment 10%
Safety Defects Backlog Size 3%
Percentage of PM to CM 30%
Preventative Maintenance Compliance 15%
Apply Static Weightings To All KPIs Within Each Risk Control Area
Calculate Score Between 0 and 4 For
Each KPI
Group Governance ProcessCascade up approach...
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All Sites
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Operational Risk Group (ORG)Governance of Process Safety established across business...
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Monthly meeting
Dedicated to reviewing technical risks
AgendaReview Process Safety IncidentsProcess Safety KPIs Performance ReviewTechnical RisksBenchmarkingRegulatory Changes
Key Learning PointsFrom ScottishPower’s journey to date...
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