How is safety connected to safety? What is safety and why is it important

How is safety connected to safety?What is safety and why is it important.

Heidi Fuglum

ABB - Chemical, Oil and Gas Market Development & Technology Deployment Manager

Moscow, Russia | 16-19 June, 2014


Introducing Heidi Fuglum

•Working with ABB since 1996

•Heidi has been with ABB for more than 15 years and is currently Technology Coordinator for Chemical, Oil and Gas. She lives in Oslo (Norway) but she spends most of her time in the Arab Gulf region. Her responsibilities are development of the automation market, both for new installations and installed base. Heidi is also responsible for safety systems in installed base.

•Heidi has worked on an oil platform for one year in Norway, and she has resided in Jakarta (Indonesia) and in Singapore.

•She is certified functional safety engineer from TUV


Why is safety so important?


The energy we love to hate

•Equivalent 136.000 TWh

•~ 1000 times Norwegian electricity production

•~ 6000 nuclear power plant blocks, open one each week for 115 years.

Source: International Energy Agency (IEA)


Carbon emissions from different sources

Coal continues to account for the largest share of energy-relatedcarbon dioxide emissions throughout the projection

Source: Energy Information Administration (EIA)

World energy-related carbon dioxideemissions by fuel type – 1990-2040 (billion metric ton)


The energy we love to hate

•Largest windfarm planned is 200 mills at 2 MW with annual production 1,2 TWh

•To replace oil and gas consumption, 113.000 such farms, with a total of 23 million mills is needed.

•At 100 meters distance, this will go 60 times around equator

Source: International Energy Agency (IEA)


Longer, deeper, colder… and olderEnsuring safe, efficient and sustainable operations


Key concepts to managing safetyProcess (Technical) Safety

Functional Safety

Personal or Occupational Safety Managing Major Accident Hazards, with particular focus on managing the

containment of hydrocarbons and chemicals

Slips, trips & fallsPersonel Protection EquipmentLockout-tagoutConfined space workingHot working Instrumented

Functional Safety

Product Safety

Overall Safety Management & Culture

Interlocks, Alarms & Trips

Safe for Intended Use

Human FactorsAlarm managementHuman failure modesDesigning out problemsBehavioral safetyCompetency management


Safety fundamentalsHazard and Risk

Hazard has the potential to cause harm through

• Injury

• Illness

• DamageRisk is a combination of

• The probability of occurrence of harm

• The severity of the harm

•Want to reduce risk to protect:

• People

• Environment

• Business


Risk matrix

ConsequenceCategory Risk MatrixCategory 5

Extremely Serious

TOLERABILITY BAND

No action necessary

- If ALARP

Category 4

Major Consequence

TOLERABILITY BAND

No action necessary

- If ALARP

Category 3

Sev ere

Consequence

TOLERABILITY BAND

No action necessary

- If ALARP

Category 2

Serious

Consequence

TOLERABILITY BAND

No action necessary

- If ALARP

Category 1

Signif icant

Consequence

TOLERABILITY BAND

No action necessary

- If ALARP

1 2 3 4 5

10-7 10-6 10-5 10-4 10-3 10-2 10-1 1 10

Extremely Very Unlikely Possible Probable

Unlikely Unlikely Unlikely

1 2 3 4 5

High Risk

Low Risk

Likelihood


Risk matrixConsequence

Category

Category 5Extremely Serious

TOLERABILITY BAND

No action necessary- If ALARP

Category 4Major Consequence

TOLERABILITY BAND


Category 3Sev ere

Consequence

TOLERABILITY BAND


Category 2Serious

Consequence

TOLERABILITY BAND


Category 1Signif icant

Consequence

TOLERABILITY BAND


1 2 3 4 5

10-7 10-6 10-5 10-4 10-3 10-2 10-1 1 10

Extremely Very Unlikely Possible ProbableUnlikely Unlikely Unlikely

1 2 3 4 5

Likelihood

Process Safety

High

LowPersonalSafety

Major Incident Triangle

Personal Incident Triangle

Consequence Major incident

ConsequenceHigh Potential Incident

IndicatorDetail breachesConsequence

Unsafe actsvIndicator

Near misses

ConsequenceMinor injury

Consequence Major incident

Personal vs Major incidents, indicators

Source: Woodgroup


Protection is multiple protection layers

Risk Reduction using LOPA

Emergency response layer

Passive protection layer

Active protection layer

Safety layerEmergency shutdown

Process shutdown

Processvalue

Trip level alarm

Process control layer

Process alarm

Process control layerNormal behaviour

Plant and EmergencyResponse

Dike

Relief valve,Rupture disk

SafetyInstrumentedSystem

OperatorIntervention

Basic ProcessControlSystem


Key concepts to managing safetyProcess (Technical) Safety

Functional Safety

Personal or Occupational Safety Managing Major Accident Hazards, with particular focus on managing the

containment of hydrocarbons and chemicals

Slips, trips & fallsPersonel Protection EquipmentLockout-tagoutConfined space workingHot working Instrumented

Functional Safety

Product Safety

Overall Safety Management & Culture

Interlocks, Alarms & Trips

Safe for Intended Use

Human FactorsAlarm managementHuman failure modesDesigning out problemsBehavioral safetyCompetency management


Different types of safetyHealth, Safety and Environment


The Subsea Factory – environmental challenges


Different types of safetyProcess Safety


Different types of safetyFunctional Safety (“Automation Safety”)

Controller

Level Switch

Solenoid

Pump

SIF A

SIF B

SIF C

SIF D

Safety Instrumented System with multiple SIF’s


Different types of safetyFunctional Safety

IEC 61511

•Defines 61508 application in Process Sector

•Defines the Application of Safety Instrumented Systems for the Process Industry


Different types of safetyProduct Safety


Why focus on operators?Operator effectiveness generates substantial savings

Global process industry looses $20 billion (5% percent of annual production) due to unscheduled downtime and poor quality

80% of these losses are preventable, 42% result primarily from operator error

Huge increase in amount of information dramatically increases risk for stress in critical situations

Distribution of unscheduled shutdowns and slowdowns in %


The evolution of operator controlSignificant increase in complexity and span of control


Different types of safetyHuman Factors

• Who’s hurt, who just needs a cuddle, who should I pick up first?

• What should I do?

• When Mathias starts crying, why does Peter always start crying as well?


Different types of safetyHuman Factors

• Hundreds of screaming babies….and we expect the operator to register and respond to all babies that are hurt?

• Alarm Management essentials - make sure the operator picks up the right baby every time.


Different types of safetySafety Culture

SafetyCommunication

SAFETY

CULTURE

Management commitment

Supervisory commitment

Teamwork

Safety rules& procedures

Workforce involvement

Training

OrganizationalLearning

ReportingSystem

Workpressure


Source: Energy Information Administration (EIA)


How can we get the energy supply we need in a safe and sustainable way?

Oil and Gas•Electrification•Subsea

Power Grid Smart Community•Shore to Ship

Industry automation•Data Centers

Documents

How is safety connected to safety? What is safety and why is it important