HSE in Design

Best Practice Forum July 2007

HSE in Design Anonymous quote from a fitter Bass Strait

If you want something simple, made ##### difficult get an engineer involved!!

TheKnack-_Harris.mpg

HSE in Design What does the term HSE in design mean to us? The technical side of HSE (using sophisticated tools (rightly) for managing the risks in design) QRA, EIA,HAZOP, HAZID,ENVID,HEMP, SIL standard tools supported by software programmes used for achieving statutory compliance and design safety intent however not used throughout industry sectors! On the other hand the more agricultural aspect of HSE e,g, field execution rely on PPE and JHAs etc.

HSE in Design

Challenger; Piper Alpha; Texas City; Bhopal.

What is happening here?

Front End

Sharp End
JHA, JSA Stepback 5x5

Event

PTW

PPE, BOPs Just Culture

Current Focus

HSE in Design The events are memorable and often lead to recommendations/statutes on design requirements

Texas City Texas City

Piper Alpha Piper Alpha

HSE in Design The fact is that many accidents occur related to design issues they dont make headlines, dont get fed back into the organisation and therefore dont provide impetus for change This presentation illustrates several examples, one where a design feature failed and one where a design specification was not included It will also give some thought on the transition from engineering to Construction and where areas of risks can occur

Case Study Field Engineering Erection of Structural Steel Design intent was to hold the gratings in by welded brackets - fitted during fabrication An added safety feature to secure the grating prior to clipping

Case Study As the structure was torqued up what happened? The Gratings rode over the bracket and created a greater hazard! What was the decision made at that time? Back to basic and not fit the brackets The design caused a deviation from standard working practice e.g. Access was allowed/Clips not fitted

Conclusion Steel erection Foreman allowed pipefitters into the area to string out pipework He advised them the structure wasnt torqued He stepped onto a grating which moved and he fell to his death There were other factors but the design initiated the chain of events that led to someones death

2nd study
LNG plant Specification called for non-return valves to be fitted for charging the systems Final design didnt include these valves not ordered Punch listing by customer identified that the valves were not fitted Hundreds of valves were ordered and fitted as a priority Some were sticking

2nd study Recharging a glycol wet leg system System (operated at 48 Bars) with valve isolations Relief valve not operated so couldnt refill against the head of pressure Connected to the drain lines (traditional method) Opened relief valve when he still couldnt charge On completion his Colleague operated the main supply valve by mistake The system became pressured and blew the bottom out of the charging can, hitting the technician in the face

HSE in Design What is common to both incidents?

The engineers responsible will never know

HSE in Design Engineering exerts a major influence on an EPCM project Too much engineering can impact on construction schedules, creating higher levels of risk (The mad scramble) Field Engineering changes made without the appropriate safety reviews A word on CDM 1994

Evolution of HSE 1980s

TECHNOLOGY

1990s
TECHNOLOGY MANAGEMENT SYSTEMS

2000+
TECHNOLOGY MANAGEMENT SYSTEMS BEHAVIOUR

Engineering Engineering

Construction Construction

Zero harm

Time

Practical Considerations Preliminary project risk assessment what you are going to build, where its going to be built, who is going to build it and what resources are needed - Example if scaffolding is a problem, design in the access Get the engineers into the field, most never see what they design Hold design reviews and involve the right balance of people (not just for safety) Prior to an engineering safety review, take timeout for a safety moment Have a common project risk register that doesnt stop at Detailed Design

Conclusion HSE in design is not just about integrity and reliability of the product It affects the whole project - construction, commissioning and eventual maintenance The state we want is;

If you want something difficult made simple, get an engineer