BP Group
Process Safety Training
BP Vietnam
October/November 2007
Peter Gedge BP Exploration, Aberdeen
John Atherton Process Safety Consultant
Course Admin
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fire exit / drills
washrooms
start time
finish time
breaks
mobile phones to silent mode please, or OFF
laptops OFF
slide-pack will be locally available
questions at any time
enjoy, challenge and participate
Introductions
Lets get off to a good start
Introduce yourself
Name & Role
Background
Agenda
Day 1
Day 2
Day 3
Day 4
Concepts and Hazard Identification
Risk Assessment & Engineering Controls
Operations, HF, MoC, ER, Investigation,
Audit
Management and Wrap-up
Exercises and Videos
Course Quiz
Feedback
Course Objective
To teach basic concepts of Process Safety.
To provide a basic knowledge and understanding
of process hazards in operating plants.
To illustrate the value of industrial accident
case studies in managing process safety.
To describe how Process Safety can be
managed
What is
Process Safety?
Definition of Process Safety
Process Safety is a disciplined framework for
managing the integrity of hazardous operating
systems and processes by applying good design
principles engineering and operating practices.
It deals with the prevention and control of
incidents that have the potential to release
hazardous materials or energy. Such incidents can
cause toxic effects, fire or explosion and could
ultimately result in serious injuries, property
damage, lost production and environmental impact.
How BP Manages Process Safety?
No accidents, no harm to people
& no damage to the environment
Getting HSE Right
HSE
PROCESS SAFETY
PSM
PERSONAL SAFETY
Control of
Work
Standard
Integrity Management
Standard
Driving
Standard
Marine
Standard
Segment Guidelines
Why PS?
VIDEO
Pemex 1984
and
Pasadena 1989
Esso Longford
BP Grangemouth 1987
Some Recent BP Incidents
Temsah Ignited
Blowout
Mardi Gras
In Salah
Whiting Pipe
Still
Mersin tank
fire
Thunderhorse
Texas City
bpTrinidad
Texas City
Ultraformer
BTC
Substances?
What are the
dangerous substances
in your business?
Process Safety Concepts
Hazardous Incident Scenarios
Process Safety addresses the potential release
of hazardous substances caused by:
MECHANICAL FAILURES
PROCESS UPSETS
PROCEDURES / HUMAN ERROR
LEAKS
SPILLS
MECHANICAL FAILURE
FIRE
EXPLOSION
TOXIC EFFECTS
INJURIES
DAMAGE
BUSINESS LOSS
Process Integrity
Knowledge and understanding of your process.
What is the operating envelope for each process?
How much variation in feedstock and operating
conditions is tolerable?
Plant and Equipment
Can the plant and
equipment fail?
Is it possible to predict
the probable outcome of
a failure?
How can you prevent and
control failure?
Incident Distribution
Catastrophic Loss
10
Major Incidents
30
Serious Incidents
600
Minor Incidents
+ 1000 Near Miss Incidents
Iceberg Concept
PHYSICAL
CAUSES
WATER
LINE
Beneath the surface of any
incident lies the real cause
and the solution to
preventing a recurrence.
Understanding Incidents
An incident is any unplanned, unexpected event
which results in significant loss.
Incidents involve the release and direct contact of
hazardous substances with people, equipment and
the environment.
What is the impact from an incident?
Injure People, Damage Environment
Damage Equipment and Facilities
Cause Business Loss
Business closure
Hazard barrier diagram
H
A
Z
A
R
D
TO P EVENT
BARRIERS
BARRIERS
ESCALATION
ESCALATION CONTROLS
CONTROLS
C
O
N
S
E
Q
U
E
N
C
E
Stages of safety
Effectiveness in Risk
Reduction
Appraise
Select
Define
Inherent
Safety
Execute
Engineered
Safety
Research Phase
Procedural
Safety
Engineering Phase
Conception
Operate
Approval
Operating Phase
Startup
~ 4 years
25+ years
Layers of Protection
Process selection, process materials,
operating conditions, layout, spacing
Design features, mechanical integrity,
control scheme, safe operating procedures
Safeguards: Relief and blowdown, alarms,
ESDs
Safeguards can reduce the impact of an
incident and reduce vulnerability to loss.
Remember! Safeguards cannot make a
system safe.
Layers of Safety
PPE
EMERGENCY RESPONSE
PHYSICAL
SAFEGUARDS
OPERATING PRACTICES
CONTROL STRATEGY
ENGINEERING
PRACTICES
TECHNOLOGY
OP CONDITIONS
Inherent Safety Principles
Intensification
Substitution
Attenuation
Simplification
Less inventory
Lower hazard materials
Reduce operating severity
Simplify design
Inherently safer systems are less likely to
incur serious process incidents.
Process Safety Management
Leadership / Accountability
Process Safety Information
Process Risk Management
Engineering Systems
Process & Mechanical Integrity
Management of Change
Pre-Startup Safety Review
Operating Procedures
Training / Competence
Employee Participation
Contractor Management
Safe Work Practices
Emergency Preparedness
Incident Investigation
Process Safety Knowledge
Process Safety Audit
