Process Safety

I. Rainaldi
HSE Convention, 4th June 2013
Process Safety and Asset Integrity

ƒ Process Safety is the part of Asset Integrity related to the prevention of Major
Incidents i.e. incidents that can result in multiple fatalities and/or severe
damage to the asset.
asset

ƒ Asset Integrity is the ability of the asset to perform its required functions
effectively and efficiently to achieve the business objectives, whilst
safeguarding people, the environment and the Company reputation for the
entire lifecycle.

Asset
Integrity

Process
Safety

Occupational
Safety

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Process Safety

ƒ Process Safety deals with High Severity – Low Frequency Risks

Consequence Increasing Annual Frequency

0 A B C D E

vironment

eputation
<10-6 occ /y 10-6 to 10-4 occ/y 10-4 to 10-3 occ/y 10-3 to 10-1 occ/y 10-1 to 1 occ/y >1 occ/y
Severity

Assets
People

A
Has occurred at Has occurred Happens several Happens several
Env
S

Re
Could happen in Reported for E&P
least once in several times in times/y in times/y in one
E&P industry industry
Company Company Company location

1 Slight
Slight Slight
health effect Slight effect Area of continuous improvement
damage impact
/ injury

2 Minor health
Minor Minor
effect / Minor effect
damage impact Area ALARP
injury

3 Major health
Local Local
effect / Local effect
damage impact
injury

4
PTD(*) or 1
Major effect
Major National Area that requires short term risk
fatality damage impact reduction measures
5
Multiple Extensive Extensive Internationa
fatalities effect damage l impact

Major Accident Hazard typical risk ranking region

3
 Process Safety vs. Occupational Safety

CONSEQUENCES

Process Safety

Major Accident
Hazard
(multiple fatalities)
Occupational Safety

Slips, Trips, Falls

(single fatality)

Very unlikely Possible

LIKELIHOOD

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Process Safety Management

Process Safety is managed according to a PLAN-DO-CHECK-ACT cycle, as the

other HSE processes, through the entire lifecycle (Exploration, Development,
Op a o )
Operation).

•Hazard •Procedures
identification •Operating
andd risk
i k Instructions
assessment •Standards
PLAN DO

ACT CHECK
•Management •Incident
review investigation
•Audit

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1. Plan – Hazard identification and risk assessment

ƒ Risks must be assessed during the entire lifecycle

ƒ D
During
i project
j t Phases
Ph specific
ifi Safety
S f t studies
t di and
d analysis
l i mustt be
b performed:
f d
ƒ Fire and Explosion Risk Analysis (FERA)
ƒ Quantitative Risk Assessment (QRA)
ƒ Escape Evacuation and Rescue Analysis (EERA)
ƒ HazOp
ƒ HazId
ƒ etc. typical
QRA output
ƒ Reference document
“HSE minimum design requirements”

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1. Plan – Hazard identification and risk assessment

ƒ In operation

BART
Baseline Risk Assessment Tool

Four Main Steps

Risk Risk Risk Risk
Identification Analysis Evaluation Treatment
Plant Major Incident Major Incident
Action Plan
Configuration
Co gu a o Scenarios
Sce a os Scenarios
Risk Reduction
Preventive and
Process Incident frequencies strategy
recovery safety
Characteristics and consequences barriers

3rd Step
1st Step 2nd Step 4th Step
Current
Plant Modelling Initial Risk Future Risk
Risk

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2. Do – Implementation and operation

Safety Critical Element (SCE)

ƒ part of an installation or plant (including computer programs):

ƒ the failure of which could cause or contribute substantially to a Major
Incident;
ƒ a purpose of which is to prevent, or limit the effect of, a Major Incident.

Performance Standard (PS)

ƒ statement, which can be expressed in qualitative or quantitative terms, of

the performance required of a system, item of equipment or computer
program in order for it to satisfactorily fulfil its purpose.

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2. Do – Implementation and operation

Other elements of Process Safety implementation:

p g manuals and p
ƒ Operating procedures

ƒ Management of change

ƒ Inspection and maintenance

ƒ Staff Competence, Training & Awareness

ƒ Emergency preparedness

ƒ Selection and management of Contractors and Suppliers

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3. Check – Control and corrective actions

Process Safety implementation is checked by means of:

ƒ Audit
ƒ Inspections
ƒ Key Performance Indicators
ƒ Analysis and investigation of incidents and near-misses

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4. Act - Management Review

ƒ During the Management Review the status of programs for Process Safety risks
reduction must be analyzed and, if necessary, new objectives and targets must
be established, both at Subsidiary and Headquarter level.

Continuous
Improvement

Management Policy
Review

Planning
Control and
corrective actions

Implementation
and Operation

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How to determine and manage costs of Major Accident

The total cost of a barrel can be expressed as the sum of inherent costs and
risked costs.

Process Safety Risk

Asset Risk
Residual Risk Costs Occupational Risk

RISKED
(ALARP Region) Environmental Risk
Reputational Risk
Cost to reduce
intolerable risks

ΔNPV (worst case event at the time of analysis)

Operative Costs (including

ENT

Insurance; current + predicted)

INHERE

Decommissioning Costs

Development Costs (current + predicted)

Exploration Costs (current + predicted)

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