safety engineering for oil gas industry operational plant

TECHNICAL MEETTECHNICAL MEETTECHNICAL MEETTECHNICAL MEET----

TAMILNADU TAMILNADU TAMILNADU TAMILNADU

ENGINEERS FORUM, ENGINEERS FORUM, ENGINEERS FORUM, ENGINEERS FORUM,

KUWAITKUWAITKUWAITKUWAIT

TECHNICAL MEETTECHNICAL MEETTECHNICAL MEETTECHNICAL MEET----

TAMILNADU TAMILNADU TAMILNADU TAMILNADU

ENGINEERS FORUM, ENGINEERS FORUM, ENGINEERS FORUM, ENGINEERS FORUM,

KUWAITKUWAITKUWAITKUWAIT

Safety Engineering for Oil & Gas Industry Operational Plants

J RAMESH BABU

Private and Confidential

AGENDAAGENDA

About Cholamandalam MS Risk Services Ltd.About Cholamandalam MS Risk Services Ltd.

Safety Engineering studies for Operational plantsSafety Engineering studies for Operational plants

Case studiesCase studies


CMSRS SERVICES POTFOLIOCMSRS SERVICES POTFOLIO


Services Offered by CMSRS Contd.,Services Offered by CMSRS Contd.,


Our Global Foot PrintsOur Global Foot Prints


Global Risk Technology Center [GRTC]Global Risk Technology Center [GRTC]


AccoladesAccolades


WINNER OF RISK MANAGER OF THE YEAR AWARDWINNER OF RISK MANAGER OF THE YEAR AWARD


NAPESCO our partner in Kuwait

a leading national oil field services provider


OTHER ACCOLADESOTHER ACCOLADES

APPROVED HEALTH & SAFETY CONSULTANTS FOR KUWAIT APPROVED HEALTH & SAFETY CONSULTANTS FOR KUWAIT OIL COMPANY UNDER 31 S CATEGORY ( ONLY ASIAN OIL COMPANY UNDER 31 S CATEGORY ( ONLY ASIAN COMPANY)COMPANY)

APPROVED FOR CONSULTANCY STUDIES AT KUWAIT APPROVED FOR CONSULTANCY STUDIES AT KUWAIT NATIONAL PETROLEUM COMPANY ON PROJECT TO NATIONAL PETROLEUM COMPANY ON PROJECT TO PROJECT BASISPROJECT BASIS

APPROVED FOR CONSULTANCY STUDIES AT AL KHAFJI APPROVED FOR CONSULTANCY STUDIES AT AL KHAFJI JOINT OPERATIONS OF SAUDI ARAMCO OIL COMPANY AT JOINT OPERATIONS OF SAUDI ARAMCO OIL COMPANY AT SAUDI ARABIA ON PROJECT TO PROJECT BASISSAUDI ARABIA ON PROJECT TO PROJECT BASIS


Risk Based Inspection

Identification of risks of each equipment on the risk matrix

Selection of type of maintenance and frequency of inspection


Risk & Reliability Management - Concept


RRM Process


Standards adopted

API publication 581- Base Resource Document: Risk Based Inspection

API 580 Recommended Practice for Risk Based Inspection


Health Safety Environment Critical Equipment System (HSECES) for Refinery and Off shore Facilities


HSECES

HSE Critical Equipment and Systems (HSECES)

Parts of an installation and such of its structures, plant equipment and systems (including computer programmes) or any part thereof, the failure of which could cause or contribute substantially to; or a purpose of which is to prevent or limit the effect of a major accident or any accident with severe or catastrophic consequences


CRITICAL EQUIPMENT


Fire Safety Audit / Fire Risk Assessment

Identification of fire risks and assessment of fire risks based on Risk Assessment technique suggested by Fire Precautions at Workplace Act, UK

Recommendation of fire prevention measures

Fire / smoke spread hazards and suggesting control measures

Review of Passive Fire Protection System (PFPS)

Identification of heat / smoke detection requirements

Review of Active Fire Protection System (AFPS) as per TAC & NFPA standards


Fire & Explosion Hazard Management system


Process of FEHM


CHAZOP STUDY FOR ELECTRICAL/ ELECTRONIC/ PL SYSTEMS

OBJECTIVE

To analyze the types of failure modes of new system (independently and in conjunction with other new/existing equipment) and to ensure that sufficient redundancy/fall back arrangement is provided and the introduction of the new system does not result in unsafe plant operation

SCOPE

Hazards and Operability Study, HAZOPS, is a Systematic Structured Discovery technique to identify hazardous consequences due to deviations from designers intentions. The scope of the study covers all the Instruments and Control systems like DCS, ESD, Field Instruments, Local Control Panel, UPS, paging system, etc. including new design andrevamping of existing facilities.

The study will also undertake a Safety Integrity Level (SIL) assessment for all safety related electrical/ electronic/ programmable electronic systems


PROCESS SAFETY AUDITS/ SAFETY AUDITS

Comprehensive Safety Audit as per IS 14489 /OHSAS 18001

Review of 31 SMS elements

Combination of Engineering and System based solutions

Comprehensive Approach similar to that of a health check up

Should address ground level realities

Should have performance based approach

Can be objective (Adoption of Scoring Pattern)


Process Safety Management

14 Elements of PSM

Employee Participation

Process Safety Information

Process Hazard Analysis

Operating Procedures

Training

Contractors

Pre-startup Safety Review

Mechanical IntegrityHot-work PermitsManagement of ChangeIncident InvestigationsEmergency Planning & ResponseCompliance Safety AuditsTrade Secrets


Safety Perception Survey

SPS part of culture change management, a step

further to OHSAS 18001, to understand employees

safety perception better

Specific SPS questionnaire for each employee category

Developed a software to analyze survey data collected

Carried out SPS for a 9 MMTPA refinery93.75

90.62

72.5

0

62.5

79.83 79.21

84.55 83.8586.59

0

10

20

30

40

50

60

70

80

90

100

Category 1 93.75 90.62 72.5 0 62.5

Category 2 79.83 79.21 84.55 83.85 86.59

EMPLOYEE EMPOWERMENT

MANAGEMENT CLIMATE MANAGEMENT

COMMITMENT QUALITY OF

SUPERVISON RECOGNITION OF

PERFORMANCE


Disaster Management Planning

Disaster Management Plan can be evolved

as per standards US EPA, NFPA 1600,

local statutes and corporate standards

Should be scenario based

Specific and detail procedures should be

developed

Periodically rehearsed

Periodically updated


ELECTRICAL SAFETY AUDIT

Comprehensive Electrical Safety Reviews

(Earthing, ESD, HAC, Lightning, accidents, protection,WPs, sample tests)

Lightning Protection Reviews

Electrical Hotspot Detection Surveys

Thermographic Surveys


LIGHTNING PROTECTION REVIEW

Review of LP based on IS 2309 /NFPA 780/API RP 2003/OISD 180

Use of LP Risk Assessment software, based on BS 6651

Risk Based design preferred


Thermography Surveys

Part of E-RBM Programme

In the De-Tariff scenario, may be offered free by ge neral insurance companies

Identification of potential survey points / equipme nt and interpretation - very crucial

NFPA 70 E recommends Thermographic surveys


Accident Investigation


The Aim of the Investigation

THE KEY RESULT SHOULD BE TO PREVENT A RECURRENCE OF THE SAME ACCIDENT


INVESTIGATION STRATEGY

GATHER INFORMATION & ESTABLISH FACTS

ISOLATE ESSENTIAL CONTRIBUTORY FACTORS

DETERMINE CORRECTIVE ACTIONS

IMPLEMENT CORRECTIVE ACTIONS


Accident Investigation Techniques

Fault Tree Analysis

Fishbone / Ischikawa Diagram

Why Why Analysis


Fault Tree Analysis

Private and ConfidentialFish bone / Ischikawa Diagram


F a i l s t o i n s p ec t

N o r e c o g n i t i o n p l a nI n a d e q u a t e t r a i n i n g p l a n

N o a c c o u n t a b i l i t y p o l i c y N o i n s p e c t i o n p o l i c y

N o d i s c i p l i n e p r o c e d u r e s

O u t d a t e d h a z c o m p r o g r a mN o o r i e n t a t i o n p r o c e s s

U n g u a r d e d ma c h i n e

H or s e

p l ay

F a i l s t o t r a i nT o m u c h

w o r k

D e f e c t i v e P P EF a i

l s to r e

p or t i

n j ur y

I n a d e q u a t e t r a i n i n g

C r ea t e

a h az a r d

F a i l s t o e n f o r c e

U n t r a i n e d w o r k e r

B r o k e n t o o l sI g n o

r e a h a z

a r d

L a c k o f t i m e

I n a d e q u a t e l a b e l i n g

N o r e c o g n i t i o n

C u t sB u r n s

Lack

of v

isio

n

S t r a i n s

No

mis

sion

sta

tem

ent

C h e m i c a l s p i l l

17


Moving towards Excellence

Imma

ture

Orga

nizati

ons

Time

TQ

M M

atu

r ity

Ad-Hoc Annual AuditsAd-Hoc Management Reviews

Ad-hoc Training

SHEQ Strategic Planning

ISO 9000. ISO 14001, OHSAS 18001Satisfaction Surveys,

Supporting MIS

Ad-Hoc Risk Assessments

Measurement ProgramImprovement program

Stage 1CrisisManagement

Crisis Management

Stage 3Enlightenment

Behavior basedInterventions

Stage 4Wisdom

Self Assessments

Sustainability

Stage 5Certainty

10 12 Years

Stage 2Awakening(Cosmetic)

Low

Hig

h

Business Processes Mapped

safety engineering for oil gas industry operational plant

Documents

risk assessmentidentification

kuwait oil company

consultancy studies

asian oil company

risk matrixselection

project basispage

project basissaudi arabia

inspection page