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BP Group

Process Safety Training


BP Vietnam

October/November 2007

Peter Gedge BP Exploration, Aberdeen


John Atherton Process Safety Consultant

Course Admin
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fire exit / drills


washrooms
start time
finish time
breaks
mobile phones to silent mode please, or OFF
laptops OFF
slide-pack will be locally available
questions at any time
enjoy, challenge and participate

Introductions
Lets get off to a good start
Introduce yourself
Name & Role
Background

Agenda
Day 1
Day 2
Day 3
Day 4

Concepts and Hazard Identification


Risk Assessment & Engineering Controls
Operations, HF, MoC, ER, Investigation,
Audit
Management and Wrap-up

Exercises and Videos


Course Quiz
Feedback

Course Objective
To teach basic concepts of Process Safety.
To provide a basic knowledge and understanding
of process hazards in operating plants.
To illustrate the value of industrial accident
case studies in managing process safety.
To describe how Process Safety can be
managed

What is
Process Safety?

Definition of Process Safety


Process Safety is a disciplined framework for
managing the integrity of hazardous operating
systems and processes by applying good design
principles engineering and operating practices.
It deals with the prevention and control of
incidents that have the potential to release
hazardous materials or energy. Such incidents can
cause toxic effects, fire or explosion and could
ultimately result in serious injuries, property
damage, lost production and environmental impact.

How BP Manages Process Safety?


No accidents, no harm to people
& no damage to the environment
Getting HSE Right
HSE
PROCESS SAFETY
PSM

PERSONAL SAFETY
Control of
Work
Standard

Integrity Management
Standard

Driving
Standard
Marine
Standard

Segment Guidelines

Why PS?

VIDEO
Pemex 1984
and
Pasadena 1989

Esso Longford

BP Grangemouth 1987

Some Recent BP Incidents


Temsah Ignited
Blowout

Mardi Gras

In Salah

Whiting Pipe
Still

Mersin tank
fire

Thunderhorse

Texas City

bpTrinidad

Texas City
Ultraformer

BTC

Substances?

What are the


dangerous substances
in your business?

Process Safety Concepts

Hazardous Incident Scenarios


Process Safety addresses the potential release
of hazardous substances caused by:
MECHANICAL FAILURES
PROCESS UPSETS
PROCEDURES / HUMAN ERROR

LEAKS
SPILLS
MECHANICAL FAILURE

FIRE
EXPLOSION
TOXIC EFFECTS

INJURIES
DAMAGE
BUSINESS LOSS

Process Integrity
Knowledge and understanding of your process.
What is the operating envelope for each process?
How much variation in feedstock and operating
conditions is tolerable?

Plant and Equipment


Can the plant and
equipment fail?
Is it possible to predict
the probable outcome of
a failure?
How can you prevent and
control failure?

Incident Distribution

Catastrophic Loss

10

Major Incidents

30

Serious Incidents

600

Minor Incidents

+ 1000 Near Miss Incidents

Iceberg Concept

PHYSICAL
CAUSES
WATER
LINE

Beneath the surface of any


incident lies the real cause
and the solution to
preventing a recurrence.

Understanding Incidents
An incident is any unplanned, unexpected event
which results in significant loss.
Incidents involve the release and direct contact of
hazardous substances with people, equipment and
the environment.
What is the impact from an incident?

Injure People, Damage Environment


Damage Equipment and Facilities
Cause Business Loss
Business closure

Hazard barrier diagram


H
A
Z
A
R
D

TO P EVENT

BARRIERS
BARRIERS

ESCALATION
ESCALATION CONTROLS
CONTROLS

C
O
N
S
E
Q
U
E
N
C
E

Stages of safety

Effectiveness in Risk
Reduction

Appraise

Select

Define

Inherent
Safety

Execute

Engineered
Safety

Research Phase

Procedural
Safety

Engineering Phase

Conception

Operate

Approval

Operating Phase

Startup

~ 4 years

25+ years

Layers of Protection

Process selection, process materials,


operating conditions, layout, spacing

Design features, mechanical integrity,


control scheme, safe operating procedures

Safeguards: Relief and blowdown, alarms,


ESDs

Safeguards can reduce the impact of an


incident and reduce vulnerability to loss.

Remember! Safeguards cannot make a


system safe.

Layers of Safety
PPE
EMERGENCY RESPONSE
PHYSICAL
SAFEGUARDS

OPERATING PRACTICES
CONTROL STRATEGY
ENGINEERING
PRACTICES
TECHNOLOGY
OP CONDITIONS

Inherent Safety Principles


Intensification
Substitution
Attenuation
Simplification

Less inventory
Lower hazard materials
Reduce operating severity
Simplify design

Inherently safer systems are less likely to


incur serious process incidents.

Process Safety Management

Leadership / Accountability
Process Safety Information
Process Risk Management
Engineering Systems
Process & Mechanical Integrity
Management of Change
Pre-Startup Safety Review
Operating Procedures

Training / Competence
Employee Participation
Contractor Management
Safe Work Practices
Emergency Preparedness
Incident Investigation
Process Safety Knowledge
Process Safety Audit