Prepared by Michael Jones July 2019 Process Safety When looking at safety incidents they typically fall into two categories Category 1 Personal safety Normally higher in frequency but lower in consequence ID: 1030044
Download Presentation The PPT/PDF document "Introduction to Process Safety" is the property of its rightful owner. Permission is granted to download and print the materials on this web site for personal, non-commercial use only, and to display it on your personal computer provided you do not modify the materials and that you retain all copyright notices contained in the materials. By downloading content from our website, you accept the terms of this agreement.
1. Introduction to Process SafetyPrepared by: Michael JonesJuly 2019
2. Process SafetyWhen looking at safety incidents, they typically fall into two categoriesCategory 1: Personal safetyNormally higher in frequency but lower in consequenceCould involve low volumes of hazardous or toxic materialsOn most occasions worst case scenario is a single fatality
3. Process SafetyCategory 2: Process SafetyLower frequency – higher consequence eventsResult in multiple fatalities or catastrophic environmental eventsDue to loss of containment involving significant quantities of hazardous (flammable or toxic) materials
4. Process SafetySome process safety incidents1984: Bhopal, India: >3,000 fatalities & 700,000 citizens affected – release of methyl isocyanate1988: Piper Alpha, North Sea: 167 fatalities – oil exploration1989: Pasadena, Texas: 23 fatalities & 314 injuries - polyethylene plant2005: Texas City, Texas: 15 fatalities & 180 injuries - petroleum refinery2005: Buncefield Oil Storage Terminal, Hempstead, UK: zero fatalities & 43 injuries2010: Macondo Deepwater Horizon, Gulf of Mexico: 11 fatalities & 16 injuries – oil exploration2012: Williams Olefins Plant: 2 fatalities & 114 injuries - petrochemical plant 2013: The West, Texas, fertilizer plant: 15 fatalities (first responders and public) & 160-200 injuries
5. Process SafetyWorkSafe NZ have focused on the recommendations from the 2005, Buncefield Oil Storage Terminal TNZ have reviewed the Buncefield recommendations in its SFAIRP review
6. Process SafetyWhat hazardous materials at TNZ could lead to a Process Safety event?
7. Process SafetyMajor Incidents identified for the terminal?MI-01 - Loss of containment of gasoline from wharf pipeline with subsequent ignition resulting in fire/ explosion. MI-02 - Loss of containment from gasoline storage tank (Tank 2, 3, 4, 5 and 6) with subsequent ignition resulting in fire/ explosion. MI-03 - Loss of containment from ethanol storage tank (Tank D1 and F1) with subsequent ignition resulting in fire/ explosion. MI-04 - Full surface fire on gasoline storage tank (Tank 2, 3, 4, 5 and 6). MI-05 - Full surface fire on ethanol storage tank D1. MI-06 - Loss of containment of gasoline from pumps and piping with subsequent ignition resulting in fire/ explosion. MI-07 - Loss of containment of ethanol from pumps and piping with subsequent ignition resulting in fire/ explosion. MI-08 - Loss of containment of gasoline at the loading gantry with subsequent ignition resulting in fire/ explosion. MI-09 - Loss of containment of ethanol at the loading gantry with subsequent ignition resulting in fire/ explosion. MI-10 - Loss of containment of butane from the underground storage tank with subsequent ignition resulting in fire/explosion. MI-11 - Loss of containment of butane from road tanker or loading hose with subsequent ignition resulting in fire/ explosion. MI-12 - Loss of containment of butane from product transfer pump and piping with subsequent ignition resulting in fire/ explosion. MI-13 - Escalation to TNZ facilities from external site resulting in fire/ explosion.
8. Process SafetyMajor Incident escalation events ESC-01 - Escalation onsite - Escalation of major incident to other flammable inventories onsite. ESC-02 - Escalation offsite - Escalation of major incident at TNZ to external site / adjacent Major Hazard Facilities. Major Hazard Facilities within 2 Km of TNZ
9. Permit to work breach/failureChanges without ‘Management of change’Incorrect or inadequate critical drawingsActivation of emergency safety deviceActivation of pressure relief valveActivation of high level tank alarmAny crack or pinhole in process pipingUnexpected, extreme corrosionUnauthorised deactivation of protection systems/alarmsSafety Critical Element fails to operate on demandPrimary loss of containment resulting in release of material/productIncidents involving release of energy or toxic materials that under slightly different conditions could have resulted in a catastrophic eventCreation of ignition sourceCatastrophic eventFatalityLoss of containment - release of material/productHigh impact incident – sustained releaseSerious harm injuryFirst aid and near missesProcess safety exceptions Unsafe acts/conditions and Process safety deviationsMedical treatment injuriesPersonal safetyProcess safetyProcess SafetyIncidents which could result in Process Safety event.
10. Catastrophic eventFatalityProcess Safety“Focus on that which is important as opposed to interesting”Thoroughly investigate all incidents which could result in Process Safety eventAny event resulting in a loss of containmentUnexpected or extreme corrosionWork permit breachesFailure of Safety Critical Element to operate on demandActivation of a Safety Critical Element Unauthorised work on a Safety Critical Element or unauthorised deactivation of alarm systemBreach in bulk tank Safe Fill Level or activation of tank level alarm
11. Critical elements of a Process Safety programmeFocus on safety criticalEquipmentProcessesPersonnelProcedures and practicesHazardIncident
12. TNZ’s HSEQ Management SystemProcess Safety Critical Element
13. Critical items of a Process Safety programmeCritical asset and component inspections and testing to ensure integrity of primary and secondary product containmentFormal verification of safety critical elementsMetal fatigue management programmeTank filling and product transferHazardIncident
14. Critical items of a Process Safety programmeAsset management programmeMechanical integrity management plansSafety in designAlarm management programmePipeline integrity management system Pipeline and bulk tank corrosion protection controlsReporting and investigation of all Process Safety incidents HazardIncident
15. Critical items of a Process Safety programmeManagement of Change (MoC)Increase in incidents during change Covers new – temporary – emergency situationsFormal process when not changing ‘like for like’MoC undertaken before the change is implementedRisk based – consultative approach to identify and manage potential issues
16. Critical items of a Process Safety programmeWork PermitWherever possible, investigate ways to undertake the activity so a work permit is not required e.g.Can the work be undertaken outside the hazardous area?Is there a cold work option available rather than undertaking hot work?Can the item be lowered to the ground as opposed to doing work at height?Competency of Work Permit Issuers and Work Permit ReceiversCalibrated and bump tested portable gas detectorsUse of approved contractors to undertake work
17. Critical items of a Process Safety programmeSafety Critical Element (SCE)A SCE is any part of the facility or its plant (including a computer program)…That has the purpose of preventing, or limiting the effect of, a major incident, andThe failure of which could cause or contribute substantially to a major incident.SCEs and their maintenance programmes have been reviewed by independent and competent persons to verify that safety-critical elements are or will be suitable and will remain in good repair and condition throughout the life cycle of the facilityAnnual verification of SCEs by independent person - IEM ltd Inspections LimitedNo unauthorised work is permitted to be undertaken on a Safety Critical Element without the prior approval being given from either the TNZ Manager or Terminal OperatorAny new or proposed modifications to SCEs shall be managed through the Management of Change processRefer TNZ Procedure 13.6 for the inspection and verification of Safety Critical Elements
18. Critical items of a Process Safety programmeTraining and competencyOnly staff and contractors who are confirmed as being competent are allowed to operate within the terminalWhere full competency has not be attained, suitable controls (e.g. supervision) must be put in placeTerminal Operators have personalised training schedule, which incorporates expectations around Process Safety
19. Critical items of a Process Safety programmeEmergency responseDetailed in TNZ’s Emergency Preparedness and Response Procedure (refer Stellar Library – TNZ folder 9.1.1)Major Incident scenario have been addressed in the Emergency Preparedness and Response Procedure Terminal Manager has assigned roles and responsibilities in the event of emergency (review of TNZ’s Emergency Preparedness and Response Procedure)Three emergency exercises per year (2 x desktop and 1 x simulation)
20. Process Safety – WorkSafe reportingNotifiable eventAny of the following events that arise from work:a deatha notifiable illness or injury ora notifiable incident.Notifiable illness or injuryThese are specified serious work-related illnesses or injuries.All injuries or illnesses which require a person to be admitted to hospital for immediate treatment are notifiable.The other types of injuries and illnesses that also require notification are set out on WorkSafe’s website.
21. Process Safety – WorkSafe reportingNotifiable incident An unplanned or uncontrolled incident in relation to a workplace that exposes the health and safety of workers or others to a serious risk arising from immediate or imminent exposure to:a substance escaping, spilling, or leakingan implosion, explosion or firegas or steam escapinga pressurised substance escapingelectric shock (from anything that could cause a lethal shock, for example it would not include shocks due to static electricity, from extra low voltage equipment or from defibrillators used for medical reasons)the fall or release from height of any plant, substance, or thingdamage to or collapse, overturning, failing or malfunctioning of any plant that is required to be authorised for use under regulationsthe collapse or partial collapse of a structurethe collapse or failure of an excavation or any shoring supporting an excavationthe inrush of water, mud, or gas in workings in an underground excavation or tunnelthe interruption of the main system of ventilation in an underground excavation or tunnela collision between two vessels, a vessel capsize, or the inrush of water into a vesselany other incident declared in regulation to be a notifiable incident, for example those listed in:regulation 6 of the Health and Safety At Work (Asbestos) Regulations 2016Schedule 5 of the Health and Safety At Work (Mining Operations and Quarrying Operations) Regulations 2016regulation 33 of the Health and Safety At Work (Major Hazard Facilities) Regulations 2016regulation 70 of the Health and Safety at Work (Petroleum Exploration and Extraction) Regulations 2016.Additional reporting requirement for Major Hazard FacilitiesAn unplanned or uncontrolled incident in relation to a workplace that exposes a worker or any other person to a serious risk to that person’s health or safety arising from an immediate or imminent exposure to…An unplanned event (other than a false alarm) that requires the emergency plan to be implemented:An event that does not cause, but has the potential to cause, a major incident:Damage to, or failure of, a safety-critical element that requires intervention to ensure it will operate as designed.
22.