Sreejith Offshore Training pack
One Day Offshore Safety Training
Pillai Sreejith
Sreejith Offshore Training pack
•Major accidents do happen around the world, some of them recent, have caused us to ask if they can happen to us – and they certainly can!
•We need to ensure they do not happen to us by:
• Re-emphasising our safety management system;
• Updating our existing Field safety Case; and
• Ensuring you all know about it!!
Why this training?
Sreejith Offshore Training pack
What will we learn today?
• The difference between occupational/personal and process safety;
• What is a major accident;• What is and what is in an offshore Safety Case;• What are the safety barriers / controls/ systems/
Safety Critical Systems (SCE) that prevent major accidents;
• The part we all must play in preventing major accidents; and
• Test our understanding of what we have learned through Piper Alpha accident.
Sreejith Offshore Training pack
• Piper Alpha
• 1988 – Major fire and explosion
• 167 people died
• Caused by PTW failure, PFP flaws and layout issues
• Bombay High
• 2005 – MSV collision with platform and major fire
• 11 People died
• Caused by riser damage from MSV impact
• Texas City Refinery
• 2005 – petroleum distillate overflowed causing explosion & flash fire
• 14 People died
• Caused by maintenance & process start-up flaws
Major Accidents in Oil & Gas Industries
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Recent Major Accidents in your offshore Field?
Please include details of major accidents (and near-misses) that occurred in your installation/s to tell the participants the need for them to be cautious. Include photographs if you have.
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Major Modifications
• List down the major modifications (process / marine) that occurred in your offshore installation/s in the past 1 year to tell them that the risk profile has changed:– Examples:
• Flare system modifications• Addition of a hydrocarbon process equipment• Change in mooring system• Addition of gas compression facilities
Sreejith Offshore Training pack
What is a safety case?
• Operators of offshore installations want to be sure that their operations are safe and do not expose their people or their business to unacceptable levels of risk;
• Plant modifications, variations on operating conditions and new ownership mean that the risk picture is changing; and
• Regulators and other stakeholders ask you to justify the continuing operation of the installation through safety cases.
Sreejith Offshore Training pack
Corporate HSE Management System
Show your HSEMS through a flow chart or a diagram to explain how periodic risk assessment/s are done to update safety case, as part of global sustainability reporting / CSR.
Sreejith Offshore Training pack
Offshore Safety Case Update project
• Key steps involved:
• Offshore site visit (to assess the safety critical element / barrier performance);
• Risk Assessment (using realistic field inputs such as barrier performance to be used in QRA event gates in frequency analysis); and
• Safety Case update
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1 day Training Contents
• Difference between Occupational /personal and Process & Marine Safety;
• What is a major accident?; • Major Offshore accident case studies;
– Piper Alpha– Mumbai High Platform– BP Texas Refinery
• Potential Major accidents for offshore complex;• Offshore Safety Case;• Safety Barriers in the offshore complex / installation; and• Safety training assessment.
Sreejith Offshore Training pack
Breaks for the day
• 10.30 am: Tea / Coffee Break
• 12.30 to 1.30 pm: Lunch break
• 3.30 pm: Tea / Coffee Break
Sreejith Offshore Training pack
Once the safety systems /barriers fail, there can be major
accidents!!!Only you can operate and
maintain safety systems without flaws.
Key Message
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Session Break
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Occupational /Personal, Marine and Process Hazards
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Learning objectives•To understand major accidents;
•To understand the difference between occupational/personal, marine and process hazards;
• To understand the ‘Swiss Cheese’ accident causation model and ‘Bow Tie’ barrier concept;
• To learn the importance of barriers in controlling major accidents
and
• To appreciate the need to maintain the safety systems in order to control / mitigate major accidents.
Sreejith Offshore Training pack
Are these terms too obvious and more of a commonsense issue?
If so, why are we discussing this?
Discussion trigger: BP Texas findings by Mr. Baker panel.
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Major Accident(UK HSE SC Regulations,2005 )
• A ‘Major Accident’ defined by UK HSE is:– A fire, explosion or the release of a dangerous substance
involving death or serious personal injury to persons on the installation or engaged in an activity or in connection with it;
– An event involving major damage to the structure of the installation or plant affixed thereto or any loss in the stability of the installation;
– The collision of a helicopter with the installation;– The failure of life support systems for diving operations in
connection with the installation; and– Any other event arising from a work activity involving death or
serious personal injury to five or more persons on the installation or engaged in an activity in connection with it.
Sreejith Offshore Training pack
Major AccidentsExamples
• Deadliest accident so far: 1988 Piper Alpha (167 fatalities);
• 2nd deadliest: 1980 Alexander L. Kielland Accommodation rig capsized during a storm (123 fatalities);
• 3rd deadliest: 1989 Seacrest drillship capsized during a typhoon (91 fatalities ); and
• 9th Deadliest: 2005 Mumbai High Platform fire (22 fatalities).
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Potential Major Accidents in your Offshore Field
• Examples –please customize– Blowouts– Riser & Pipeline releases– Process Hydrocarbon Releases – Fire & Explosion– Ship Collision– Dropped Objects– Transportation Accidents– Helicopter crash– Projectile/Missile impact– Structural damage– Turret Failure– Cargo Tank explosion
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Occupational Hazards
• Personal or Occupational Health and Safety Hazards– Can give rise to incidents or accidents that primarily affect
one individual worker for each occurrence
• Personnel injury from:– Slips, trips and falls;– Electrical shocks;– Adverse effects from high noise/heat/dust/fumes;– Minor cuts / bruises; and– Struck-by objects.
• Generally OH are avoided by wearing PPEs & following procedures
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Occupational Accidents• Mainly those accidents that can be
controlled by the use of PPEs
Source courtesy: Internet
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Process Safety & Marine Hazards
• Process and Marine Safety Hazards– Can give rise to major accidents that can have
catastrophic effects and can result in multiple injuries and fatalities, as well as substantial economic, property and environmental damage
• Examples of these are:– Fires / Explosions– Helicopter crash– Dropped objects damaging structure or FPSO hull– Un-ignited gas releases– Ship collisions– Riser / pipeline ruptures
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Safety Performance OH & PSH
• Performance for occupational safety is measured through (eg.) lost time injuries (LTI); and
• Performance for process safety is measured process safety equipment performance, hydrocarbon releases, fires, etc.
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Process Safety Accident
BP Texas City Refinery Fire and Explosion (15 killed, 180 injured)
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Marine Accident
Ship collision in Japanese waters causing major damage(July 27, 2007)
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Loss IcebergSource courtesy: Internet
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Bow-tie Barrier ConceptEvents andEvents and
CircumstancesCircumstancesHarm to people and Harm to people and damage to assets damage to assets
or environmentor environment
HHAAZZAARRDD
CCOONNSSEEQQUUEENNCCEESS
BARRIERS
Major accidentMajor accident
Construction /Engineering activitiesMaintenance activitiesOperations activities
Source courtesy: Internet
Sreejith Offshore Training pack
Barriers for Potential Major AccidentsTHREATS CONTROL &
PREVENTATIVE BARRIERSMITIGATIVE BARRIERS CONSEQUENCE
MAE
Instrumentation, i.e. TAHH / LALL /
LAHH / PALL / PAHH
Relief System (PSV)
Navigational Aids
Pedestal Cranes
Inert Gas System
Miscellaneous / Temporary Equipment
F & G System
F & G Detectors
ESD system
ESD Valves
Wellhead Isolation
Blowdown Valves
ESD Manual Pull Stations
HVAC
Manual Water Fire Fighting Equipment
Deluge System
Manual Foam Fire Fighting Equipment
Blowdown Valves
ESD Manual Pull Stations
Firewalls
Firewater Pumps
Firewater Ring main
Gaseous Systems
Emergency Lighting
Emergency Power (UPS)
Internal Communications
& Alarms
External Communications
Helideck Crash Equipment
Miscellaneous Safety
Equipment
Safe Refuge (Muster Area)
Escape Routes
TEMPSC & Life rafts
Helicopter Facilities
Direct to Sea Equipment
Control
Detection
Mitigation
Emergency response
CMMS
PTW
PreventativeBlowout(Surface blowouts)
Riser Pipeline Releases
Process Hydrocarbon Releases
Ship Collision
Dropped Objects
Helicopter Crash
Projectile/missile Impacts
Structural Environmental events
Transportation Accidents
Major Potential Accidents
Turret failure
Cargo tank explosionsIgnition control
Audits
Inspections
Maintenance
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Do you know where these safety barriers are in your installation/s?
• Fire walls (are they A or H or J type? What does these alphabets mean?; if there is A 60 fire wall, is this acceptable? Why?)
• Blast walls (are blast and fire walls same? How are their locations decided?)
• Flame / flash back arrestors
• ESD push buttons
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Safety BarriersExplanation-Example 1
• Ignition Control– Hazardous Area Classification– Use of Ex type equipment (do you know how they are
designed? Why can’t they be designed as vapour / gas tight?)
– Flash back arrestors, spark arrestors– Static charge discharge control (bonding, when do
you install bonding? Why is this done?)– Lightning control (how do you control these hazards?)– Inert gas system for cargo tanks– Use of inert gas system to dilute hydrocarbon vapours
at vents
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• What are the difference between Passive Fire Protection (PFP) & Active Fire Protection (AFP)?
• Examples of PFP?– Fire walls– In tumescent coatings (ESD valves?)– Heat shields on the escape routes?
• Examples of AFP?– Deluge– FM 200 Gaseous Fire Fighting system– Fire & Gas Detection system
Safety BarriersExplanation-Example 2
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Fire walls, Blast walls, Heat Shields
Source courtesy: Internet sources
A 60 Firewall
J 45/ H60, 0.3 bar Blast wall
Blast wall in place Heat Shield
Sreejith Offshore Training pack
Source courtesy: Internet
Sreejith Offshore Training pack
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Prevention barriers Mitigation barriers
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Discuss
• For major accident control, which side of the bow tie should be strong? Left (prevention) or the right side (mitigation) ? Why?
Major Accident
Discussion trigger: Can a gas explosion be effectively mitigated prevented with water deluge?
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Learning
• Major accidents;• Potential major accidents at your offshore
installation;• Difference between personal / occupational,
marine and process accidents;• Swiss Cheese & Bow Tie safety concepts; and• Importance of safety barriers in controlling major
accidents.
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Session Break
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Learning Objectives
• To learn about the major accidents that occurred in your offshore complex to understand ‘What went wrong?”; and
• To think about the potential barrier failures that might exist at offshore installations which could lead to potential major accidents.
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Offshore Complex
• Show the field diagram
• Show the platforms / FPSOs and the interconnecting pipelines
• Include the major additions / modifications to highlight to the participants that the installation has changed over the years
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Platform Accident Details
• Show the accident & near-miss trends (bar chart) and discuss cause breakdown (pie-chart)
• A graph that shows no particular trend (upward or downward) could mean:– The HSE is not under control;– The HSE performance / accident data collection /
analysis is not proper;– No one knows what will be the future HSE
performance is!
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Major Accidents• Identify major accidents, hi-potential incidents, near-misses;
• Discuss each of the major cases from the detail reports to explain:– Causes– Consequences– Risk reduction recommendations– Implementation status– Any similar accidents occurred?
• If there are any photos of these accidents, show them.
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CausesExamples
• Inadequate planning / organization;• Flaws in PTW procedures;• Written job procedure did not anticipate
contributing factors;• Failure to follow known job procedure (s);• Inadequate training;• Supervisor failure to identify unsafe condition;
and• Failure to communicate.
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Learning
• If no concrete action is taken to rectify the cause of the incident permanently, it might lead to an accident next time round – History has proven this;
• Accidents could happen even with safety barriers in place;
• Personnel play an extremely important role in promoting safety – competency, experience and knowledge is important; and
• We need to ensure that the safety barriers are maintained so as to control / mitigate accidents.
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Session Break
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Potential Major Accident Events
at
Your Offshore Complex
In this presentation, the typical potential major accidents for FPSO / platform are included. This will require customisation in line with the field QRA results.
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Learning Objectives
• To learn about the potential major accidents that can occur in offshore field and to understand the consequences;
• To be aware of the major risk contributors at offshore installations; and
• To be aware of the risk levels for various personnel at your offshore field.
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Potential Major Accidents 1
Examples
1. Surface Blowout
2. Riser / Pipeline Releases
3. Process HC Releases –Fires / Explosions
4. Ship collisions
5. Dropped Objects
6. Transportation Accidents
Source courtesy: Internet
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Potential Major Accidents 2Examples
7. Helicopter crash
8. Projectile / Missile impact
9. Structural damage
10. Turret Failure
11. Cargo Tank Explosion
Source courtesy: Internet
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Risk Terminology
• Individual Risk (IR)
Individual Risk Per Annum is the frequency with which an individual may be expected to sustain fatal harm due to exposure to specific hazards in a year
Source courtesy: Internet
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ALARP Triangle
Source courtesy: Internet
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What does risk mean?
Source courtesy: Internet
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Essential data used in Quantitative Risk Assessment
(QRA)• Manning distribution
• Transportation details
• Heat & Material Balance diagram
• P&IDs
• PFDs
• General Arrangement / Layouts
• Design basis and safety philosophies
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• Show the areas considered in the QRA
• Explain the manning distribution of various personnel categories in the areas
• Tell them the risks calculated is rather realistic since we have considered more facts
Offshore Installation Areas
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Fires and Explosions
• Pool Fire
• Jet fire
• Vapour Cloud Explosion
• Flash Fire
Explain the causes and consequences of each type of fires including their impairment potential
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Impairment
• Discuss impingement and impairment from pool and jet fires
• Pool fire impingement on steel structures: – 10 minutes
• Jet fire impingement on steel structures: – 5 minutes
Courtesy: CMPT QRA Guidelines
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Risk assessment Flow Chart
Sectionalisation: Review PFDs, UFDs & P&IDs to separate the process and utility system to various isolatable
sections.
HAZID: Identify potential hazards
Causal Analysis: Identify hazardous events associated with accidents
Risk reducing measures: Apply enhanced or additional control measures and mitigation
measures.
Frequency Analysis and Event Tree Analysis: Frequency of each accidental event (top
event) and branch probabilities are assigned to event tree and outcome event frequency are
estimated.
Consequence Modelling: Using the software. The physical effects and damages for each outcome
event are estimated
Impact Assessment: Analyse the fire and explosion impact to structures and
equipment.
•Risk AssessmentFatality Estimation: Determine the risk to personnel from each outcome event.•Risk Summation and Risk Ranking: Sum the risks to individual from each outcome events for hydrocarbon and non-hydrocarbon hazards and identify the dominant risk contributors.Risk Assessment: Compare the risk levels against Individual Risk Acceptability Criteria to determine whether additional measures are necessary to reduce risks to ALARP.
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Potential Major Accidents
Offshore Field
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Causes:
Failure of choke valve
Failure of X’Mas tree / DHSV / SCSSV
Presence of ignition sources
Consequences:
Jet Fire
Major asset damage
Multiple fatalities / injuries
MAE 1 Surface Blowout
Source courtesy: Internet
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Source courtesy: Internet
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Subsea blow out
Source courtesy: Internet
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Fire Contours
• Show the jet, pool fire contours superimposed on the offshore installation layout drawing to show them the potential effects.
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Causes:
Failure of lifting equipment (overload / damaged lifting equipment)
Failure of crane equipment (overload, etc.)
Lifting without following procedures / controls
Consequences:
Asset damage (hull, equipment, platform, etc.)
Multiple fatalities / injuries
MAE 5 Dropped Objects
Source courtesy: Internet
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Transportation Accidents
Helicopter, boat, personnel transfers
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ANOA FIELD
Source courtesy: Internet
Risks from transportation
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MAE 6 Transportation AccidentsCauses:
Mechanical failure of boats / helicopter/ flights
Extraneous weather conditions
Material defects of personal transfer baskets or associated lifting tackles
Consequences:
Asset damage (hull, equipment, platform, etc.)
Multiple fatalities / injuries
Source courtesy: Internet
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•Protection from side & vertical impacts?
•Personnel falling from height due to giddiness, loss of grip, high wind, loss of balance, etc.
Personnel Basket Transfers
Is there an option?
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MAE 7 Helicopter Crash
Causes:
Failure of helicopter (engine failure / extreme weather)
Failure of communication equipment
Fire / explosion in FPSO / Platform
Pilot error
Consequences:
Fire
Major asset / helicopter damage
Multiple fatalities / injuries There are hardly any known occurrences of Helicopter crashing into FPSO or platform
Source courtesy: Internet
Sreejith Offshore Training pack
Source courtesy: Internet
Sreejith Offshore Training pack
MAE 8 Projectiles / MissilesCauses:
Failure of equipment due to overpressure
Inadequate design
Missiles / projectiles from gas turbines and FPSO steam turbines
Consequences:
Asset damage (hull, equipment, etc.)
Multiple fatalities / injuries
Source courtesy: Internet
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Source courtesy: Internet
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Causes:
Structural failures due to extreme weather
Corrosion
Inadequate design
Crane boom collision
Consequences:
Asset damage
Multiple fatalities / injuries
MAE 9 Structural Events
Source courtesy: Internet
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MAE 9 Structural Events
Source courtesy: Internet
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MAE 9 Structural Events
Source courtesy: Internet
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MAE 10 Turret Failure
Source courtesy: Internet
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MAE 11 Cargo Tank Explosion
FPSO
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Overall Risk for Offshore Complex
• Explain the Individual Risk (IR) for the various personnel categories;
• Explain the PLL (Potential Loss Of Life) values for the complex and various personnel categories;
• Discuss if the IR value is within the ALARP tolerable region;
• Explain the major risk contributors for the offshore complex;
• Explain what is base case IR, and ALARP IR cases (sensitivity cases); and
• Explain what is traffic light system and how is it used to determine Realistic Risk levels?
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What is Traffic Light system?
Traffic Light system is used as an assessment tool by UK HSE, NOPSA, etc.
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Traffic lights system and performance of safety systems
• Traffic light system was used to assess the performance of safety systems;
• The performance of safety systems were determined based on:– Critical maintenance test results;– Accidents / incidents;– Maintenance backlogs; and– Offshore audit findings.
How will the TL System used to calculate impairment / event frequencies in QRA?
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Traffic Light Interpretation
Tolerable
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Earlier risk IR 1
Base case risk IR 2
Risk after Safety System performance Assessment IR 3
Potential residual risk after improvements IR 4
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Learning
• Individual Risk for all offshore personnel are within the acceptable limits;
• Understanding potential major accidents for offshore installations (causes and consequences);
• Understanding the major risk contributors at offshore field; and
• Understanding the personnel risk levels for various categories.
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Session Break
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Learning objectives
•To understand the objective of Safety Cases;
•To understand ‘The UK HSE Offshore Installations (Safety Case) Regulations 2005’;
•To understand the typical SC update triggers; and
•To know the Typical Safety Case contents.
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Safety Case-Definition
“A documented body of evidence that provides a convincing and valid argument that a system is adequately safe for a given application in a given environment”
Safety Case exists for Nuclear, Offshore, Aviation, and Rail industries
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Safety Case Origin(post 1988 Piper Alpha explosion)
“UK Offshore Operators, says Cullen, must adopt this new philosophy on safety, producing a ‘Safety Case'. This includes continuous hazard assessment over the plant's lifetime, fault tree analysis, which looks at all the ways an error could develop, and takes account of ways that 'human factors' contribute to disasters”
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Safety Case Evolution Timeline
Forthwith: Immediate, at once
Lord Cullen recommended that the 4 (FEA, ESSA, EERA,SIGA) be carried out by the offshore operators immediately before the 1992 safety case regulation was released.
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Why Offshore Safety Case?
• Operators of offshore installations want to be sure that their operations are safe and do not expose their people or their business to unacceptable levels of risk;
• Plant modifications, variations on operating conditions and new ownership mean that the risk picture is changing; and
• Regulators and other stakeholders ask you to justify the continuing operation of the installation through safety cases.
• Regulatory compliance is essential to your business
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Safety Case
• First SC Regulations came into force in 1992;
• Cullen Forthwith studies:– A Fire Risk Analysis;– An assessment of the risk of ingress of smoke
or gas into the accommodation;– A review of the ability of emergency systems
to withstand severe accident conditions; and– An evacuation, escape and rescue analysis.
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The UK HSE Offshore Installations (Safety Case) Regulations 2005
• Key changes introduced by the 2005 Regulations include:
-The requirement for duty holders to send an early design notification, instead of a design safety case, to HSE when establishing a new production installation; -Duty holders are required to carry out a thorough and fundamental review of their safety cases at least every five years, or as directed by HSE; -The present requirement to re-submit safety cases every three years has been removed (inspectors will be checking to see that safety cases are being kept up to date through inspection); -New duties require licensees to ensure anyone they appoint as an operator is capable of fulfilling their legal responsibilities for safety; -Combined operations safety cases have been replaced by notifications, which do not need HSE acceptance; and -The Offshore Installations (Safety Representatives and Safety Committees) Regulations have been amended to extend consultation with safety representatives to reviewing and revising a safety case, as well as preparing one.
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Typical Contents of Safety Case
• Facility description
• HSE Management system
• Formal Safety Assessment (FSA) Summary
• Safety Critical elements and Performance Standards
• ALARP Demonstration
• Fitness to Operate
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Safety Case Update TriggersExamples
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Learning
• Origin and objectives of Safety Case;
• Piper Alpha Accident & Safety Case;
• ‘The UK HSE Offshore Installations (Safety Case) Regulations 2005;
• Typical SC contents; and
• Typical SC update triggers.
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Session Break
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Safety Barriers and their Role in Controlling Major accidents
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Learning objectives
•To understand the critical role of safety barriers / safety systems in controlling major accidents using Bow-Tie diagram;•To understand safety barriers on offshore installations; •To appreciate the need to maintain the barriers through maintenance system, inspections, etc.; and•To identify and monitor performance of safety barriers through lead and lag indicators.
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Bow Tie Diagram
Source courtesy: Internet
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Barriers for Potential Major AccidentsTHREATS CONTROL &
PREVENTATIVE BARRIERSMITIGATIVE BARRIERS CONSEQUENCE
MAE
Instrumentation, i.e. TAHH / LALL /
LAHH / PALL / PAHH
Relief System (PSV)
Navigational Aids
Pedestal Cranes
Inert Gas System
Miscellaneous / Temporary Equipment
F & G System
F & G Detectors
ESD system
ESD Valves
Wellhead Isolation
Blowdown Valves
ESD Manual Pull Stations
HVAC
Manual Water Fire Fighting Equipment
Deluge System
Manual Foam Fire Fighting Equipment
Blowdown Valves
ESD Manual Pull Stations
Firewalls
Firewater Pumps
Firewater Ring main
Gaseous Systems
Emergency Lighting
Emergency Power (UPS)
Internal Communications
& Alarms
External Communications
Helideck Crash Equipment
Miscellaneous Safety
Equipment
Safe Refuge (Muster Area)
Escape Routes
TEMPSC & Life rafts
Helicopter Facilities
Direct to Sea Equipment
Control
Detection
Mitigation
Emergency response
CMMS
PTW
PreventativeBlowout(Surface blowouts)
Riser Pipeline Releases
Process Hydrocarbon Releases
Ship Collision
Dropped Objects
Helicopter Crash
Projectile/missile Impacts
Structural Environmental events
Transportation Accidents
Turret failures
Cargo tank explosions
Ignition control
Audits
Inspections
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UK HSE KP 3 Inspection Results
Source courtesy: Internet
Sreejith Offshore Training pack Source courtesy: Internet
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What is wrong at present in oil & gas industry?
• Unacceptable level of process safety related dangerous occurrences especially in relation to loss of containment incidents;
• Major hazard industry measured safety performance using LTIs!!
• Critical systems deteriorate over time without warning until they fail catastrophically; and
• Audits tend to be too infrequent and workplace inspections focus on personal safety.
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Process Safety Management System
An effective process safety management system measures performance
Key performance indicators must include appropriate indicators of process safety
performance
Source courtesy: Internet
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Permit-to-work
Inspection & Maintenance
Staff Competence
Operational Procedures
System defects
Lagging indicator
Leading indicator
Leading indicator
Lagging indicator
Lagging indicator
Lagging indicator
Leading indicator
Leading indicator
Accident Trajectory
Key Performance Indicators set to identify defects in safety systems
Source courtesy: Internet
Sreejith Offshore Training pack
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TR
OL
BLO
WD
OW
N &
RELI
EF
SYS
TEM
FIR
E &
GA
S D
ETEC
TIO
N
EM
ER
GEN
CY S
HU
TD
OW
N
AC
TIV
E F
IRE P
RO
TEC
TIO
N
PA
SS
IVE F
IRE P
RO
TEC
TIO
N
PROCESS HYDROCARBON RELEASES/FIRES/EXPLOSIONS Example
Hyd
ro C
arb
on
R
elea
ses
EX
PL
OS
ION
Main
ten
an
ce C
heck
s/te
stC
alib
rati
on
Loop
Ch
eck
sS
imu
lati
on
Au
dit
sM
OC
/EC
R
HA
CS
tati
c Ele
ctri
cA
ud
its
Loop
ch
eck
s fo
r B
DA
ud
its/
Insp
ect
ion
CFI
s on
Relie
f V
alv
es
Loop
Ch
eck
s
Dete
ctor
Calib
rati
on
s
Au
dit
sM
OC
/EC
R
CFT
on
ES
DV
Loop
Ch
eck
s
Au
dit
s/In
spect
ion
Fire
Dri
lls
Au
dit
s
CFT
on
Fir
e P
um
ps
& V
alv
es
Test
ing
of
foam
con
cen
trate
MO
C
Inte
gri
ty In
spect
ion
of
PFP
fire
walls
Au
dit
sM
OC
Pe
rfo
rma
nc
e I
nd
ica
tors
(Le
ad
ing
& l
ag
gin
g)
Sreejith Offshore Training pack
Dual Performance Assurance
Reactive Monitoring
Lagging Indicator:
Outcome Indicator
Active Monitoring
Leading Indicators:Process or
Input Indicators
Critical ProcessSafety
Risk ControlSystem
Dual Assurance - leading and lagging indicators measuring performance of each critical element of a Process Safety Management System
Source courtesy: Internet
Sreejith Offshore Training pack
How effective are YOUR safety systems?
• Traffic light system was used to assess the performance of safety systems;
• Each of the safety systems were assessed based on:– Critical Maintenance Test (CMT) results;– Accidents / incidents;– Maintenance backlogs; and– Audit findings.
Sreejith Offshore Training pack
Acc
epta
ble
Partially degraded
N
ot
acce
pta
ble
Safety Systems Performance
Traffic Light Interpretation
Tolerable
Sreejith Offshore Training pack
Offshore Audit FindingsExamples
• H 60 fire walls penetrated to pass pipes and electrical conduits
• Fire water deluge not provided for critical hydrocarbon systems / valve clusters
• Flame Detectors obstructed with pipework
• Hazardous area Classification compromised
• Ex equipment maintenance flaws
Sreejith Offshore Training pack
Safety Barrier PerformanceTHREATS CONTROL &
PREVENTATIVE BARRIERSMITIGATIVE BARRIERS CONSEQUENCE
MAE
Instrumentation, i.e. TAHH / LALL /
LAHH / PALL / PAHH
Relief System (PSV)
Navigational Aids
Pedestal Cranes
Inert Gas System
Miscellaneous / Temporary Equipment
F & G System
F & G Detectors
ESD system
ESD Valves
Wellhead Isolation
Blowdown Valves
ESD Manual Pull Stations
HVAC
Manual Water Fire Fighting Equipment
Deluge System
Manual Foam Fire Fighting Equipment
Blowdown Valves
ESD Manual Pull Stations
Firewalls
Firewater Pumps
Firewater Ring main
Gaseous Systems
Emergency Lighting
Emergency Power (UPS)
Internal Communications
& Alarms
External Communications
Helideck Crash Equipment
Miscellaneous Safety
Equipment
Safe Refuge (Muster Area)
Escape Routes
TEMPSC & Life rafts
Helicopter Facilities
Direct to Sea Equipment
Control
Detection
Mitigation
Emergency response
CMMS
PTW
PreventativeBlowout(Surface blowouts)
Riser Pipeline Releases
Process Hydrocarbon Releases
Ship Collision
Dropped Objects
Helicopter Crash
Projectile/missile Impacts
Structural Environmental events
Transportation Accidents
Turret failures
Cargo tank explosions
Ignition control
Audits
Inspections
Sreejith Offshore Training pack
Are The Barriers Being
Properly Maintained?
IDENTIFY Barriers;(SCEs)
Are They Suitable?
Maintenance Management
Major Hazard Analysis Performance
Indicators
Process Safety Management Major Hazard Analysis/Maintenance Loop
Source courtesy: Internet
Sreejith Offshore Training pack
Learning
• Concept of Safety barriers in major accident control; and
• Role of offshore personnel in ensuring integrity of safety barriers by monitoring performance indicators; and
• Performance of safety systems to control major hazards cannot be monitored using LTIs which calls for a shift in focus.
Sreejith Offshore Training pack
Once the safety systems fail, there can be major accidents!!!
Only you can operate & maintain safety systems without flaws.
Key Message