Understanding How Process Safety Differs From Personal Safety

Understanding How Process Safety Differs From Personal Safety Critical Step Towards A Safer Facility Engr. Veronica Christine Balangue - Luna PICh. E National Convention 17 -20 February 2016 © 2013 Fluor Corporation ML 20130170 -001. ppt 1

Presentation Objectives By the end of this presentation, audience should be able to: u Differentiate process safety and personal safety u Learn how understanding the fundamental difference of the two can lead to safer facility u Learn what the implications are of lack of knowledge in process safety and inability to recognize it apart from personal safety ML 20150455 -001. pptx 2

Lack of Knowledge about Process Safety u Sounds the same, but fundamentally very different! u Not too familiar u Too complicated to be understood u ‘Cannot relate’ thinking ML 20150455 -001. pptx 3

What do we mean by Process Safety? ML 20150455 -001. pptx

A Look back at Unsafe Processes Flixborough, 1974 5 ML 20150455 -001. pptx

A Look back at Unsafe Processes Bhopal, 1984 6 ML 20150455 -001. pptx

A Look back at Unsafe Processes Piper Alpha, 1988 7 ML 20150455 -001. pptx

A Look back at Unsafe Processes Maptaphut, 2012 8 ML 20150455 -001. pptx

A Look back at Unsafe Processes Valenzuela, 2015 9 ML 20150455 -001. pptx

A Look back at Unsafe Processes Tianjing, 2015 10 ML 20150455 -001. pptx

Process + Safety u Process Any activity or combination of activities around the use, storage, manufacturing, handling and movement of hazardous substances + u Safety Quality of mind of being and feeling safe and free from hazards PROCESS + SAFETY The protection of people, the Environment and property from episodic and catastrophic incidents that may result from unplanned or unexpected deviations in process conditions. It involves engineering and management skills that exceed those required for managing workplace safety. ML 20150455 -001. pptx 11

Process + Safety u Is a disciplined framework for managing the integrity of hazardous operating systems and processes by applying good design principles, engineering and operating practices. u Deals with the prevention and control of incidents that have the potential to release hazardous materials or energy i. e. loss of containment. u Such incidents that can cause toxic effects, fire or explosion and could ultimately result in serious injuries, or in an unfortunate event, fatality, property damage, lost production and can have a detrimental impact to the environment. ML 20150455 -001. pptx 12

Process Safety and Regulations WHEN 1966 1974 1976 1979 1982 1984 1986 1987 1988 1989 1992 1994 1998 2001 2003 2004 2005 2010 WHERE Feyzin, France. LPG Bleve Flixborough, UK Seveso, Italy Dioxin Bantry Bay, Ireland Ocean Ranger, Canada Mexico Bhopal, India Challenger Chernobyl, USSR Sandoz, Bale, SZ Texas City, USA Grangemouth, UK Piper Alpha Norco, USA Pasadena TX, USA La Mède, France Milford Haven, UK Longford, Australia Toulouse, France Petrobras Columbia Skikda, Algeria. LNG Texas City, US Buncefield, UK Bombay High, India Macondo, US WHAT Cyclohexane Crude ship Platform LPG Bleve Methyl isocyanate Space shuttle Nuclear powerplant Warehouse HF HCK HP/LP interface Platform Propane FCCU Ethylene/isobutane Gasoline/LPG FCCU feedstock LPG, brittle fracture Ammonium Nitrate Platform Space shuttle Gasoline ISOM Gasoline Platform Drill rig and well FATALITIES 18 28 1 50 84 600+ 20000+ 7 100+ 0 0 1 167 7 23 6 0 2 30 11 7 27 15 0 13 11 REGULATIONS First LPG prescriptive regulations EU Seveso I Directive 1982 US Chemical Emergency Preparedness Program 1985 US Emergency Planning and Community Right-to-Know Act 1986 US Chemical Accident Prevention Program 1986 US Chemical Safety Audit Program 1986 EU Seveso I Directive update 1987 US Clean Air Act Amendments 1990 UK HSE Offshore Installations (Safety Case) Regulations 1992 US OSHA 1910 -119 Process Safety Management 1992 US EPA Risk Management Program 1996 EU Seveso II Directive 1996 UK Control of Major Accident Hazard Regulations 1999 EU Seveso II update 2002 UK HSE Offshore Installations (Safety Case) Regulations 2005 API RPs on occupied buildings and vents OSHA Refinery National Emphasis Program ML 20150455 -001. pptx 13

Personal Safety vs Process Safety Personal Safety Process Safety ML 20150455 -001. pptx

Personal Safety vs Process Safety Applicability Personal Safety … to all workplace, any industry Process Safety to primarily to process industries, e. g. , § Oil and Gas § Chemical § Petrochemical § Energy/Utility (Any industry dealing with materials with intrinsically hazardous properties) ML 20150455 -001. pptx

Personal Safety vs Process Safety Hazards Personal Safety Height Difference Noise Confined Spaces Heat Stress Hot Surfaces Electricity Bio Hazards Process Safety Flammable material under pressure Toxic material under pressure Reactive material under unsafe operating conditions Natural gas from a reservoir (under very high pressure) Chemical Hazards ML 20150455 -001. pptx

Personal Safety vs Process Safety Hazard Identification. Techniques Personal Safety - Sample Techniques/Tools: § On-site hazard identification checklist § Visual inspections via audits § Job hazard analysis - Learned through training - Done in-house Process Safety - Sample Tools: § HAZID workshop § HAZOP - Requires technical skills and competency to understand hazards involved within the process - Understand activities associate with the HSE barriers - Use of 3 rd party ML 20150455 -001. pptx

Personal Safety vs Process Safety Plot on Risk Matrix Personal Safety Process Safety ML 20150455 -001. pptx

Personal Safety vs Process Safety Impacts Personal Safety Process Safety Prevention of a series of incidents Prevention of the catastrophic events ML 20150455 -001. pptx

Personal Safety vs Process Safety Pyramid Personal Safety Process Safety Prevention of a series of incidents Prevention of the catastrophic event ML 20150455 -001. pptx

Personal Safety vs Process Safety Hierarchy of Controls Personal Safety Should start here But frequently lands here As such, responsibility for hazard controls is often in hands of front line workers and supervisors Process Safety Must start here But frequently lands here As such, responsibility for hazard controls is often in hands of senior management and engineers ML 20150455 -001. pptx

Personal Safety vs Process Safety Performance Measurement Metrics Personal Safety • Personal Safety Stats e. g. OSHA’s § TRIF (Total Recordable Incident Frequency) § LTI (Lost-Time Injury) • Established metrics • Both leading and lagging indicators Process Safety • Process Safety Metrics • Metrics subject to debate, difficult to measure • A number of guidance available, still not many Operators are implementing • Both leading and lagging indicators ML 20150455 -001. pptx

Personal Safety vs Process Safety Performance Measurement Do these signs ensure your workplace is safe? ML 20150455 -001. pptx

Performance Measurement ML 20150455 -001. pptx

Performance Measurement Longford Gas Plant, 1998 u Completed about 5 million hours without an LTI u Won industry awards for this safety performance u Killed two workers, injured eight and severed the state’s gas supply for two weeks ML 20150455 -001. pptx

Performance Measurement Texas City Refinery , 2005 u Achieved significant improvement in personal safety performance u Process safety incident resulting in 15 deaths, more than 170 injuries and significant economic losses u Considered as the most serious U. S. workplace disaster of the past two decades ML 20150455 -001. pptx

Performance Measurement ML 20150455 -001. pptx

Performance Measurement ML 20150455 -001. pptx

Performance Measurement Deepwater Horizon Well Blowout u 7 years without lost time injuries u 11 people lost their lives, 17 injured and resulted in massive spill in Gulf of Mexico ML 20150455 -001. pptx

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Performance Measurement ML 20150455 -001. pptx 31

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Summary Need for mind shift! ML 20150455 -001. pptx 33

Summary u Both personal safety and process safety is important and they complement rather than replace each other. u Same level of effort and attention to managing both process and personal safety related hazards shall be provided. u Process safety hazards should be properly identified so as for them to be managed. Hence, differentiating process safety from personal safety is in order to go about this. u Neglecting the impacts of process safety hazards just because of the idea that it is too complicated to comprehend, can result in major accident events which impact a number of people, the community and environment. . ML 20150455 -001. pptx

Questions ML 20150455 -001. pptx

Plugging… ML 20150455 -001. pptx

Plugging… u Process u 6 -hr Safety Seminar by Fluor PICh. E Chapter seminar, concepts and group workshops – Building Blocks ML 20150455 -001. pptx