One Day Offshore Safety Training
Pillai Sreejith
Sreejith
Offshore Training pack
Introduction
Offshore Safety Case Training
pillai_sreejith@hotmail.com
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Offshore Training pack
Why this training?
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!!
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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.
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Offshore Training pack
Major Accidents in Oil & Gas Industries
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
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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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Offshore Training pack
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:
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Flare system modifications
Addition of a hydrocarbon process equipment
Change in mooring system
Addition of gas compression facilities
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.
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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.
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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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Offshore Training pack
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.
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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
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Offshore Training pack
Key Message
Once the safety systems /barriers
fail, there can be major
accidents!!!
Only you can operate and
maintain safety systems without
flaws.
pillai_sreejith@hotmail.com
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Offshore Training pack
Session Break
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Offshore Training pack
Occupational /Personal, Marine
and Process Hazards
pillai_sreejith@hotmail.com
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Offshore Training pack
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.
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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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Offshore Training pack
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.
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Offshore Training pack
Major Accidents
Examples
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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Offshore Training pack
Potential Major Accidents in your
Offshore Field
Examples please customize
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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
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Offshore Training pack
Source courtesy: Internet
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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Offshore Training pack
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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Offshore Training pack
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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Offshore Training pack
Source courtesy: Internet
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Loss Iceberg
Offshore Training pack
Bow-tie Barrier Concept
Events and
Circumstances
BARRIERS
H
A
Z
A
R
D
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Harm to people and
damage to assets
or environment
Major accident
Construction /Engineering activities
Maintenance activities
Offshore
Training
pack
Operations
activities
Source courtesy: Internet
C
O
N
S
E
Q
U
E
N
C
E
S
Barriers for Potential Major Accidents
CONTROL &
PREVENTATIVE BARRIERS
THREATS
MAE
Major Potential
Accidents
Blowout (Surface blowouts
Preventative
Emergency response
Safe Refuge
(Muster Area )
Riser Pipeline Releases
Mitigation
Process Hydrocarbon Releases
Instrumentation ,
i.e. TAHH / LALL /
LAHH / PALL /
PAHH
Firewater
Pumps
Ship Collision
Dropped Objects
Detection
Helicopter Crash
Relief System
(PSV )
ESD system
Inspections
Control
Firewater Ring
main
Manual Water
Fire Fighting
Equipment
ESD Valves
PTW
Navigational Aids
F&G
System
F&G
Detectors
CMMS
Pedestal Cranes
Projectile /missile Impacts
Maintenance
Inert Gas System
Structural Environmental events
Deluge System
Wellhead
Isolation
Blowdown
Valves
ESD Manual
Pull Stations
HVAC
Audits
Ignition
control
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Cargo tank explosions
Offshore Training pack
Emergency
Power (UPS )
Internal
Communications
& Alarms
Blowdown
Valves
Helideck Crash
Equipment
ESD Manual
Pull Stations
Miscellaneous
Safety
Equipment
Gaseous
Systems
Turret failure
Emergency
Lighting
External
Communications
Firewalls
Escape Routes
Manual Foam
Fire Fighting
Equipment
Transportation Accidents
Miscellaneous
Temporary
Equipment
CONSEQUENCE
MITIGATIVE BARRIERS
TEMPSC & Life
rafts
Helicopter
Facilities
Direct to Sea
Equipment
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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Offshore Training pack
Safety Barriers
Explanation-Example 1
Ignition Control
Hazardous Area Classification
Use of Ex type equipment (do you know how they are
designed? Why cant 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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Offshore Training pack
Safety Barriers
Explanation-Example 2
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
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Offshore Training pack
Fire walls, Blast walls, Heat Shields
J 45/ H60, 0.3
bar Blast wall
A 60 Firewall
Blast wall in
place
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Source courtesy:
Internetpack
sources
Offshore Training
Heat Shield
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Offshore Training pack
Source courtesy: Internet
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EXPLOSION
Audits
MOC
Integrity Inspection of PFP
firewalls
CFT on Fire Pumps & Valves
Testing of foam concentrate
MOC
Fire Drills
Audits
Audits/Inspection
CFT on ESDV
Loop Checks
Mitigation barriers
PASSIVE FIRE PROTECTION
ACTIVE FIRE PROTECTION
EMERGENCY SHUTDOWN
FIRE & GAS DETECTION
Audits
MOC/ECR
Loop Checks
Detector Calibrations
Loop checks for BD
Audits/Inspection
CFIs on Relief Valves
HAC
Static Electric
Audits
Maintenance Checks/test
Calibration
Loop Checks
Simulation
Audits
MOC/ECR
Performance Indicators
(Leading & lagging)
Prevention barriers
BLOWDOWN & RELIEF SYSTEM
IGNITION CONTROL
PROCESS INSTRUMENTATION
Hydro Carbon
Releases
Explosion / Fire Swiss Cheese Model
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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Offshore Training pack
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.
pillai_sreejith@hotmail.com
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Offshore Training pack
Session Break
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Offshore Training pack
Major Accidents
in
your Offshore Field
pillai_sreejith@hotmail.com
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Offshore Training pack
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 Training pack
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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Offshore Training pack
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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Offshore Training pack
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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Offshore Training pack
Causes
Examples
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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Offshore Training pack
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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Offshore Training pack
pillai_sreejith@hotmail.com
Session Break
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Offshore Training pack
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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Offshore Training pack
pillai_sreejith@hotmail.
com
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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Offshore Training pack
Potential Major Accidents 1
Examples
1. Surface Blowout
4. Ship collisions
2. Riser / Pipeline Releases
5. Dropped Objects
3. Process HC Releases
Fires / Explosions
6. Transportation Accidents
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Offshore
Training
pack
Source
courtesy:
Internet
Potential Major Accidents 2
Examples
7. Helicopter crash
10. Turret Failure
8. Projectile / Missile impact
11. Cargo Tank Explosion
9. Structural damage
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Offshore
Training
pack
Source
courtesy:
Internet
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
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Offshore
Training
pack
Source
courtesy:
Internet
ALARP Triangle
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Offshore
Training
pack
Source
courtesy:
Internet
What does risk mean?
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Offshore
Training
pack
Source
courtesy:
Internet
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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Offshore Installation
Areas
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
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Fires and Explosions
Pool Fire
Jet fire
Vapour Cloud Explosion
Flash Fire
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Offshore Training packof each type of fires
Explain
the causes and consequences
including their impairment potential
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
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Courtesy:
CMPT
QRA
Offshore
Training
pack
Guidelines
Risk assessment Flow Chart
HAZID: Identify potential hazards
Sectionalisation: Review PFDs, UFDs & P&IDs to separate
the process and utility system to various isolatable
sections.
Causal Analysis: Identify hazardous events associated with accidents
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 Assessment
Fatality 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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Risk reducing measures: Apply enhanced or
additional control measures and mitigation
measures.
Potential Major Accidents
Offshore Field
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MAE 1 Surface Blowout
Causes:
Failure of choke valve
Failure of XMas tree / DHSV / SCSSV
Presence of ignition sources
Consequences:
Jet Fire
Major asset damage
Multiple fatalities / injuries
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Offshore
Training
pack
Source
courtesy:
Internet
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Offshore Training pack
Source courtesy: Internet
Subsea blow out
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Offshore
Training
pack
Source
courtesy:
Internet
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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MAE 5 Dropped Objects
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
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Offshore Training pack
Source courtesy: Internet
Transportation Accidents
Helicopter, boat, personnel transfers
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Risks from transportation
ANOA FIELD
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Source courtesy: Internet
MAE 6 Transportation Accidents
Causes:
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
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Offshore Training pack
Source courtesy: Internet
Personnel Basket Transfers
Protection from side & vertical impacts?
Personnel falling from height due to
giddiness, loss of grip, high wind, loss of
balance, etc.
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Is there an option?
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
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Offshore Training pack
Source courtesy: Internet
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Source courtesy: Internet
MAE 8 Projectiles / Missiles
Causes:
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
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Offshore Training pack
Source courtesy: Internet
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Offshore Training pack
Source courtesy: Internet
MAE 9 Structural Events
Causes:
Structural failures due to extreme
weather
Corrosion
Inadequate design
Crane boom collision
Consequences:
Asset damage
Multiple fatalities / injuries
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Offshore Training pack
Source courtesy: Internet
MAE 9 Structural Events
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Source courtesy: Internet
MAE 9 Structural Events
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Source courtesy: Internet
MAE 10 Turret Failure
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Source courtesy: Internet
MAE 11 Cargo Tank Explosion
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Offshore
Training pack
FPSO
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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Offshore Training pack
om
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
Offshore Training pack
impairment / event frequencies
in QRA?
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Traffic Light Interpretation
Tolerable
Not accepta
ble
Acce
ptab
le
Partially degraded
Safety Systems Performance
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Offshore Training pack
Earlier risk IR 1
Risk after Safety System
performance
Assessment IR 3
Base case risk IR 2
Potential residual risk
after improvements IR
4
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Offshore Training pack
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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Offshore Training pack
Session Break
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Offshore Training pack
Offshore Safety Cases
pilliai_sreejith@hotmail.com
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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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Offshore Training pack
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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Offshore Training pack
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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Offshore Training pack
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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Offshore Training pack
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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Offshore Training pack
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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Offshore Training pack
Safety Case Update Triggers
Examples
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Offshore Training pack
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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Offshore Training pack
Session Break
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Offshore Training pack
Safety Barriers and their Role
in Controlling Major accidents
pillai_sreejith@hotmail.com
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Offshore Training pack
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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Offshore Training pack
Bow Tie Diagram
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Offshore
Training
pack
Source
courtesy:
Internet
Barriers for Potential Major Accidents
CONTROL &
PREVENTATIVE BARRIERS
THREATS
MITIGATIVE BARRIERS
MAE
Emergency re
Safe Ref
(Muster A
Blowout (Surface blowouts )
Preventative
Riser Pipeline Releases
Mitigation
Instrumentation ,
i.e. TAHH / LALL /
LAHH / PALL /
Inspections
PAHH
Process Hydrocarbon Releases
Firewater
Pumps
Ship Collision
Dropped Objects
Detection
Helicopter Crash
Relief System
(PSV )
ESD system
Control
Firewater Ring
main
Manual Water
Fire Fighting
Equipment
ESD Valves
PTW
Navigational Aids
Pedestal Cranes
Audits
F&G
System
F&G
Detectors
CMMS
Tur ret failures
Projectile /missile Impacts
Inert Gas System
Ignition
control
Miscellaneous /
Carg o t ank
explos
ions
Structural
Environmental
events
Wellhead
Isolation
Blowdown
Valves
ESD Manual
Pull Stations
HVAC
Manual Foam
Fire Fighting
Equipment
Emerge
Power (U
Intern
Communica
& Alar
Extern
Communica
Helideck C
Equipm
ESD Manual
Pull Stations
Miscellan
Safet
Equipm
Firewalls
TEMPSC
rafts
Gaseous
Systems
Offshore Training pack
Emerge
Lightin
Blowdown
Valves
Transportation Accidents
Temporary
Equipment
Sreejith
Deluge System
Escape R
Helicop
Faciliti
Direct to
Equipm
UK HSE KP 3 Inspection Results
Sreejith
Offshore
Training
pack
Source
courtesy:
Internet
Sreejith
Offshore
Training
pack
Source
courtesy:
Internet
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.
Sreejith
Offshore Training pack
Process Safety
Management System
An effective process
safety management
system measures
performance
Key performance indicators must include
appropriate indicators of process safety
performance
Sreejith
Offshore
Training
pack
Source
courtesy:
Internet
Key Performance Indicators set to identify defects in safety systems
Accident Trajectory
Lagging indicator
Leading indicator
Lagging indicator
Lagging indicator
Permit-to-work
Leading indicator
Inspection & Maintenance
Lagging indicator
Leading indicator
Staff Competence
System defects
Leading indicator
Operational Procedures
Sreejith
Offshore
Training
pack
Source
courtesy:
Internet
Sreejith
Offshore Training pack
EXPLOSION
PASSIVE FIRE PROTECTION
ACTIVE FIRE PROTECTION
EMERGENCY SHUTDOWN
FIRE & GAS DETECTION
BLOWDOWN & RELIEF SYSTEM
IGNITION CONTROL
PROCESS INSTRUMENTATION
Hydro Carbon
Releases
Audits
MOC
Integrity Inspection of PFP
firewalls
CFT on Fire Pumps & Valves
Testing of foam concentrate
MOC
Fire Drills
Audits
Audits/Inspection
CFT on ESDV
Loop Checks
Audits
MOC/ECR
Loop Checks
Detector Calibrations
Loop checks for BD
Audits/Inspection
CFIs on Relief Valves
HAC
Static Electric
Audits
Maintenance Checks/test
Calibration
Loop Checks
Simulation
Audits
MOC/ECR
Performance Indicators
(Leading & lagging)
PROCESS HYDROCARBON RELEASES/FIRES/EXPLOSIONS
Example
Dual Performance Assurance
Dual Assurance - leading and lagging indicators measuring
performance of each critical element of a Process Safety Management
System
Reactive
Monitoring
Lagging
Indicator:
Critical
Process
Safety
Risk Control
System
Active Monitoring
Leading
Indicators:
Process or Input
Indicators
Outcome Indicator
Sreejith
Offshore
Training
pack
Source
courtesy:
Internet
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
Traffic Light Interpretation
Tolerable
Not accepta
ble
Acce
ptab
le
Partially degraded
Safety Systems Performance
Sreejith
Offshore Training pack
Offshore Audit Findings
Examples
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 Performance
CONTROL &
PREVENTATIVE BARRIERS
THREATS
MITIGATIVE BARRIERS
MAE
Emergency re
Safe Ref
(Muster A
Blowout (Surface blowouts )
Preventative
Riser Pipeline Releases
Mitigation
Instrumentation ,
i.e. TAHH / LALL /
LAHH / PALL /
Inspections
PAHH
Process Hydrocarbon Releases
Firewater
Pumps
Ship Collision
Dropped Objects
Detection
Helicopter Crash
Relief System
(PSV )
ESD system
Control
Firewater Ring
main
Manual Water
Fire Fighting
Equipment
ESD Valves
PTW
Navigational Aids
Pedestal Cranes
Audits
F&G
System
F&G
Detectors
CMMS
Tur ret failures
Projectile /missile Impacts
Inert Gas System
Ignition
control
Miscellaneous /
Carg o t ank
explos
ions
Structural
Environmental
events
Wellhead
Isolation
Blowdown
Valves
ESD Manual
Pull Stations
HVAC
Manual Foam
Fire Fighting
Equipment
Emerge
Power (U
Intern
Communica
& Alar
Extern
Communica
Helideck C
Equipm
ESD Manual
Pull Stations
Miscellan
Safet
Equipm
Firewalls
TEMPSC
rafts
Gaseous
Systems
Offshore Training pack
Emerge
Lightin
Blowdown
Valves
Transportation Accidents
Temporary
Equipment
Sreejith
Deluge System
Escape R
Helicop
Faciliti
Direct to
Equipm
Process Safety Management
Major Hazard Analysis/Maintenance Loop
Maintenance
Management
Major Hazard
Analysis
Are The Barriers
Being
Properly
Maintained?
IDENTIFY
Barriers;
(SCEs)
Performance
Indicators
Are They Suitable?
Sreejith
Offshore
Training
pack
Source
courtesy:
Internet
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
Key Message
Once the safety systems fail,
there can be major accidents!!!
Only you can operate & maintain
safety systems without flaws.
pillai_sreejith@hotmail.com
Sreejith
Offshore Training pack
