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Global EHS
Process Safety Implementation in Huntsman
Presentation by Dr Bill Brooks
to the International Conference on Process Safety
Performance Indicators
Brussels, 1st February 2012
1
Global EHS
What Stimulated Huntsman’s Current Programme?
Two major process safety events
one external, BP Texas City, March 2005
one internal, Port Arthur Fire, April 2006
2
Global EHS
Fire - Port Arthur, TX, April 2006
Port Arthur, Texas; April 2006
3
No fatalities
No explosion – early ignition with jet fire
Ethylene cracked gas compressor feed line
ruptured due to corrosion under insulation
Global EHS
2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 Beyond
Procedures/Training
Development
Pilot
High Hazard
Sites
Medium Hazard
Sites
Low Hazard
Sites
Gap Closure
Auditing
PS Procedure Roll Out and Implementation Time Line
IMP
LE
ME
NT
AT
ION
R
OL
L O
UT
4
Global EHS 5
Risk Assessment
• Risk matrix • Process hazard
analysis • SIL assessment • Facility siting • Electrical area class • Fire risk assessment • EHS criticality • Network security
Administrative Safeguards ● Management of change ● Organizational MOC ● Qualified persons ● Operating procedures ● Incident investigation ● Mechanical integrity ● Design verification
Engineered Safeguards ● Pressure relief ● Process safety information ● Safety system design ● Safety instr. systems ● Alarm management ● Design of safety inst.
Functions
23 New PSM procedures
Global EHS
2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 Beyond
Procedures/Training
Development
Pilot
High Hazard
Sites
Medium Hazard
Sites
Low Hazard
Sites
Gap Closure
Auditing
PS Procedure Roll Out and Implementation Time Line
IMP
LE
ME
NT
AT
ION
R
OL
L O
UT
6
Global EHS
PS Incidents*: 2003-2010
7
0
40
80
120
160
200
0 0 0
Number of PS Incidents Number of Sites
12 sites 27 sites
40 sites
High Hazard Medium Hazard Low Hazard
* Internal definition; API-754 numbers would be about one third of these, or less
Global EHS
2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 Beyond
Procedures/Training
Development
Pilot
High Hazard
Sites
Medium Hazard
Sites
Low Hazard
Sites
Gap Closure
Auditing
PS Procedure Roll Out and Implementation Time Line
IMP
LE
ME
NT
AT
ION
R
OL
L O
UT
8
Global EHS
Risk Assessment
• Risk matrix • Process hazard
analysis • SIL assessment • Facility siting • Electrical area class • Fire risk assessment • EHS criticality • Network security
Administrative Safeguards ● Management of change ● Organizational MOC ● Qualified persons ● Operating procedures ● Incident investigation ● Mechanical integrity ● Design verification
Engineered Safeguards ● Pressure relief ● Process safety information ● Safety system design ● Safety instr. systems ● Alarm management ● Design of safety inst.
Functions
9
Closing the Gaps Reduces the Likelihood of an Accident
Global EHS
PS Procedure Rollout Status 5 Yr Plan
10
0% 20% 40% 60% 80% 100%
Low Risk
Medium Risk
High Risk 11 out of 12 sites
23 out of 27 sites
5 out of 40 sites
Global EHS
Progress Opposite the Baker Panel and CSB Recommendations
Topic Huntsman in 2006 Huntsman in 2012
Leadership Patchy PSM understanding
at Leadership level
Formal Executive training
package
Formal PSM governance
structure
Monthly review of KPI’s
PSM Management structure Global EHS Standards in
place – but inconsistent
interpretation of PSM
elements
New PSM management
system
Knowledge and expertise Insufficient in many parts of
Company
New Centres of PSM
Excellence
Qualified Person
appointments
Formalised Organisational
MoC process
Global EHS
Progress Opposite the Baker Panel and CSB Recommendations
Topic Huntsman in 2006 Huntsman in 2012
Accountabilities Line management
accountabilities defined in
EHS Standards
Clearer line management
accountabilities
KPI’s Metrics database New KPI’s
Executive scorecard
PSM auditing Auditing against EHS
Standards and regulatory
requirements
+ audits against new
procedures
Board monitoring EHS but not PSM-specific Monthly reports to CEO and
Leadership Team
Updates to external directors
External Internal process only Industry body participation
benchmarking
