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One Day Offshore Safety Training

Pillai Sreejith

Sreejith Offshore Training pack


Introduction

Offshore Safety Case Training

pillai_sreejith@hotmail.com

Sreejith 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!!

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


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.

Sreejith 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:
• 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
Sreejith 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.

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

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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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Session Break

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Occupational /Personal, Marine
and Process Hazards

pillai_sreejith@hotmail.com

Sreejith 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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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 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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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
Sreejith Offshore Training pack
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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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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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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Source courtesy: Internet Loss Iceberg

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Bow-tie Barrier Concept
Events and Harm to people and
Circumstances damage to assets
or environment
BARRIERS

C
O
H N
S
A E
Z Q
U
A E
R N
Major accident C
D E
S
Construction /Engineering activities
Maintenance activities
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Operations pack
activities
Source courtesy: Internet
Barriers for Potential Major Accidents
THREATS CONTROL & CONSEQUENCE
MITIGATIVE BARRIERS
PREVENTATIVE BARRIERS

MAE
Major Potential Accidents Emergency response

Blowout (Surface blowouts ) Safe Refuge


Preventative (Muster Area )
Riser Pipeline Releases
Mitigation
Escape Routes
Instrumentation , Process Hydrocarbon Releases
i.e. TAHH / LALL / Firewater
Ship Collision Pumps
LAHH / PALL / Emergency
PAHH Lighting
Dropped Objects Firewater Ring
Detection
main
Relief System Helicopter Crash Emergency
(PSV ) ESD system
Manual Water Power (UPS )
Fire Fighting
Inspections Control Equipment
Internal
ESD Valves Communications
Navigational Aids PTW Deluge System & Alarms
F&G
System Wellhead
Isolation Manual Foam External
Fire Fighting Communications
F&G Blowdown
Detectors Equipment
Pedestal Cranes CMMS Valves
Blowdown Helideck Crash
ESD Manual Valves Equipment
Projectile /missile Impacts Pull Stations

Inert Gas System


Maintenance Structural Environmental events ESD Manual
Miscellaneous
Safety
HVAC Pull Stations Equipment
Transportation Accidents
Firewalls TEMPSC & Life
Miscellaneous / rafts
Temporary
Equipment
Audits Gaseous
Helicopter
Systems
Facilities

Direct to Sea
Equipment
Turret failure

Ignition Cargo tank explosions


control

Sreejith Offshore Training pack


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 Barriers
Explanation-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

Sreejith 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

Sreejith Offshore Training pack


Fire walls, Blast walls, Heat Shields
J 45/ H60, 0.3
bar Blast wall

A 60 Firewall

Blast wall in Heat Shield


place

Sreejith Source courtesy: Internetpack


Offshore Training sources
Sreejith Offshore Training pack
Source courtesy: Internet
Hydro Carbon
Releases Performance Indicators
(Leading & lagging)
Maintenance Checks/test

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Calibration
Loop Checks
Simulation
Audits
MOC/ECR
PROCESS INSTRUMENTATION

HAC
Static Electric
Audits
Prevention barriers

IGNITION CONTROL
Loop checks for BD
Audits/Inspection
CFIs on Relief Valves

BLOWDOWN & RELIEF SYSTEM


Loop Checks
Detector Calibrations
Audits
MOC/ECR

FIRE & GAS DETECTION


CFT on ESDV

Offshore Training pack


Loop Checks
Audits/Inspection

EMERGENCY SHUTDOWN
Fire Drills
Audits
CFT on Fire Pumps & Valves
Mitigation barriers

Testing of foam concentrate


MOC

ACTIVE FIRE PROTECTION


Integrity Inspection of PFP
firewalls
Audits
MOC
Explosion / Fire Swiss Cheese Model

PASSIVE FIRE PROTECTION

EXPLOSION
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?
Sreejith 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

Sreejith Offshore Training pack


Session Break

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Major Accidents
in
your Offshore Field

pillai_sreejith@hotmail.com
Sreejith 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.

Sreejith 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
Sreejith 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!
Sreejith 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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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.

Sreejith 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.
Sreejith Offshore Training pack
pillai_sreejith@hotmail.com
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.

Sreejith 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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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

Sreejith Offshore
Source Training pack
courtesy: Internet
Potential Major Accidents 2
Examples
7. Helicopter crash
10. Turret Failure

8. Projectile / Missile impact

11. Cargo Tank Explosion

9. Structural damage

Sreejith Offshore
Source Training pack
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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Source Training pack
courtesy: Internet
ALARP Triangle

Sreejith Offshore
Source Training pack
courtesy: Internet
What does risk mean?

Sreejith Offshore
Source Training pack
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

Explain
Sreejith the causes and consequences
Offshore Training packof each type of fires
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

Sreejith Courtesy: CMPT


Offshore QRA
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 X’Mas tree / DHSV / SCSSV
Presence of ignition sources

Consequences:
Jet Fire
Major asset damage
Multiple fatalities / injuries

Sreejith Offshore
Source Training pack
courtesy: Internet
Sreejith Offshore Training pack
Source courtesy: Internet
Subsea blow out

Sreejith Offshore
Source Training pack
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

Sreejith 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

Sreejith 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

Sreejith Offshore Training pack


Source courtesy: Internet
Sreejith Offshore Training pack
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

Sreejith Offshore Training pack


Source courtesy: Internet
Sreejith 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

Sreejith 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

Sreejith FPSO
Offshore Training pack
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?

Sreejith pillai_sreejith@hotmail.c
Offshore Training pack
om
What is Traffic Light system?

Traffic Light system is used as an assessment tool by UK HSE, NOPSA, etc.

Sreejith Offshore Training pack


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
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impairment / event frequencies in QRA?
Traffic Light Interpretation

Tolerable

Partially degraded

le

ble
ptab

Not accepta
Acce

Safety Systems Performance


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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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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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Offshore Safety Cases

pilliai_sreejith@hotmail.com
Sreejith Offshore Training pack
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.

Sreejith 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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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.
Sreejith 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
Sreejith 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.

Sreejith 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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Safety Case Update Triggers
Examples

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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.

Sreejith Offshore Training pack


Session Break

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Safety Barriers and their Role
in Controlling Major accidents

pillai_sreejith@hotmail.com
Sreejith 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.

Sreejith Offshore Training pack


Bow Tie Diagram

Sreejith Offshore
Source Training pack
courtesy: Internet
Barriers for Potential Major Accidents
THREATS CONTROL &
MITIGATIVE BARRIERS
PREVENTATIVE BARRIERS

MAE Emergency re

Blowout (Surface blowouts ) Safe Ref


Preventative (Muster A
Riser Pipeline Releases
Mitigation
Escape R
Instrumentation , Process Hydrocarbon Releases
i.e. TAHH / LALL / Firewater
Ship Collision Pumps
LAHH / PALL /
PAHH
Inspections Emerge
Lightin
Dropped Objects Firewater Ring
Detection
main
Relief System Helicopter Crash Emerge
(PSV ) ESD system
Manual Water Power (U
Fire Fighting
Control Equipment
Intern
ESD Valves Communica
Navigational Aids PTW Deluge System & Alar
F&G
System Wellhead
Isolation Manual Foam Extern
Fire Fighting Communica
F&G Blowdown
Audits CMMS Detectors Equipment
Pedestal Cranes Valves
Blowdown Helideck C
ESD Manual Valves Equipm
Tur ret failures
Projectile /missile Impacts Pull Stations
Miscellan
Carg o t ank explos
Structural ions
Environmental events ESD Manual Safet
Inert Gas System HVAC Pull Stations Equipm
Ignition Transportation Accidents
Firewalls TEMPSC
control
Miscellaneous / rafts
Temporary
Equipment Gaseous
Helicop
Systems
Faciliti

Sreejith Offshore Training pack


Direct to
Equipm
UK HSE KP 3 Inspection Results

Sreejith Offshore
Source Training pack
courtesy: Internet
Sreejith Offshore
Source Training pack
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
Source Training pack
courtesy: Internet
Key Performance Indicators set to identify defects in safety systems

Accident Trajectory

Lagging indicator

Lagging indicator Leading indicator

Lagging indicator Permit-to-work

Leading indicator

Inspection & Maintenance

Lagging indicator
Leading indicator

Staff Competence

System defects Leading indicator

Operational Procedures

Sreejith Offshore
Source Training pack
courtesy: Internet
Hydro Carbon
Releases Performance Indicators
(Leading & lagging)
Maintenance Checks/test

Sreejith
Calibration
Loop Checks
Simulation
Audits
MOC/ECR
PROCESS INSTRUMENTATION

HAC
Static Electric
Audits

IGNITION CONTROL
Loop checks for BD
Audits/Inspection
CFIs on Relief Valves

BLOWDOWN & RELIEF SYSTEM


Loop Checks
Detector Calibrations
Audits
MOC/ECR

FIRE & GAS DETECTION


Example

CFT on ESDV

Offshore Training pack


Loop Checks
Audits/Inspection

EMERGENCY SHUTDOWN
Fire Drills
Audits
CFT on Fire Pumps & Valves
Testing of foam concentrate
MOC

ACTIVE FIRE PROTECTION


Integrity Inspection of PFP
firewalls
Audits
MOC

PASSIVE FIRE PROTECTION


PROCESS HYDROCARBON RELEASES/FIRES/EXPLOSIONS

EXPLOSION
Dual Performance Assurance
Dual Assurance - leading and lagging indicators measuring
performance of each critical element of a Process Safety Management
System

Reactive Critical Active Monitoring


Monitoring Process Leading
Lagging Safety Indicators:
Indicator: Risk Control Process or Input
System Indicators
Outcome Indicator

Sreejith Offshore
Source Training pack
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

Partially degraded

le

ble
ptab

Not accepta
Acce

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
THREATS CONTROL &
MITIGATIVE BARRIERS
PREVENTATIVE BARRIERS

MAE Emergency re

Blowout (Surface blowouts ) Safe Ref


Preventative (Muster A
Riser Pipeline Releases
Mitigation
Escape R
Instrumentation , Process Hydrocarbon Releases
i.e. TAHH / LALL / Firewater
Ship Collision Pumps
LAHH / PALL /
PAHH
Inspections Emerge
Lightin
Dropped Objects Firewater Ring
Detection
main
Relief System Helicopter Crash Emerge
(PSV ) ESD system
Manual Water Power (U
Fire Fighting
Control Equipment
Intern
ESD Valves Communica
Navigational Aids PTW Deluge System & Alar
F&G
System Wellhead
Isolation Manual Foam Extern
Fire Fighting Communica
F&G Blowdown
Audits CMMS Detectors Equipment
Pedestal Cranes Valves
Blowdown Helideck C
ESD Manual Valves Equipm
Tur ret failures
Projectile /missile Impacts Pull Stations
Miscellan
Carg o t ank explos
Structural ions
Environmental events ESD Manual Safet
Inert Gas System HVAC Pull Stations Equipm
Ignition Transportation Accidents
Firewalls TEMPSC
control
Miscellaneous / rafts
Temporary
Equipment Gaseous
Helicop
Systems
Faciliti

Sreejith Offshore Training pack


Direct to
Equipm
Process Safety Management
Major Hazard Analysis/Maintenance Loop

Maintenance Are The Barriers


Management Being
Properly
Maintained?

IDENTIFY
Barriers;
Major Hazard (SCEs)
Analysis Performance
Indicators
Are They Suitable?

Sreejith Offshore
Source Training pack
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

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