Bowties in process safety auditing Mireille Busque - ERM Insert then choose Picture select your picture. Right click your picture and Send to back. May 9, 2017 Copyright 2015 by ERM Worldwide Limited and/or its affiliates ( ERM ). All Rights Reserved. No part of this work may be reproduced or transmitted in any form or by any means, without prior written permission of ERM.
New CSA Z767-17 SafetyManagement 4 Pillars: safety leadership Understanding hazards and risks Risk Management Review and improvement
Safety Auditing Auditing is a vital part of a PSM program Demonstrate compliance with company expectations and processes Ensure suitable safeguarding measures in place Identify deficiencies in compliance or safeguarding measures. Needs to be systematic and independent. Must be relevant to the site hazards 3
Different types of audit Compliance-centred Regulatory Corporate Management systems Hazard-centred Focussed on particular hazards Safeguards necessary to control hazards 4
Audit protocol But developing an audit protocol can be problematic safety hazards may vary from site to site or from time to time Consequences of accident may vary and therefore different safeguards required One size does not fit all for a varied portfolio of assets Audit must consider safeguards important to prevent or mitigate site-specific process safety hazardous events 5
MR6 Using Bowties in Safety Auditing So how can you: Identify process safety measures relevant to particular sites? Account for local concerns and vulnerabilities? Leave a legacy of increased process safety awareness MR7
Slide 6 MR6 MR7 This slide should show how bowtioes meet the requirements of the previous slide Martyn Ramsden, 05/05/2016 Don't understand thsi graphic Martyn Ramsden, 05/05/2016
Some bowtie concepts Various distinct causes of the top event A physical situation with a potential for harm Realistic worstcase outcomes of the top event 7 Measures to prevent a top event due to a particular threat PREVENTION The scenario which represents losing control of the hazard Measures to mitigate the consequences of a top event MITIGATION Conditions which could cause barrier to fail
Typical use of bowties in risk management Define Safety Critical Measures Identify Safety Critical Tasks Hazard Identification Frequency Risk Ranking Risk Ranking Bowtie Analysis ALARP Are we doing enough? Consequence Define KPIs Hazard awareness training Shape audit protocols Major Accident Hazard Assessment and Management 8
Safety Cases Bowtie diagrams have many different uses: 9
Deep understanding of barrier operation Bowtie diagrams have many different uses: Part of design process Mechanical Failure/Fatigue / Erosion (e.g.vessels, equipment, piping, valves, flanges, seals) and Piping Designed/ Installed/ Commissioned to Specified Safe Operating Limits [Design Basis] PC001 Pressure Vessels PC002 Heat Exchangers PC003 Rotating PC005 Hydrocarbon Piping and Piping Operated within Specified Safe Operating Limits PC001 Pressure Vessels PC002 Heat Exchangers PC003 Rotating PC005 Hydrocarbon Piping Upset (e.g. overpressure, over temperature) Field operator regularly walking around ER009 Control & Alarms Impact Damage (Vehicle) and Piping Designed/ Installed/ Commissioned to Specified Safe Operating Limits [Design Basis] PC001 Pressure Vessels PC002 Heat Exchangers PC003 Rotating PC005 Hydrocarbon Piping Overfilling of Drums Internal Corrosion External Corrosion Seal Leak Detection and Venting System PC003 Rotating Perimeter fence to prevent access to site by unauthorized vehicles Detection DS002 Security and Piping Operated within Specified Safe Operating Limits PC001 Pressure Vessels PC002 Heat Exchangers PC003 Rotating PC005 Hydrocarbon Piping and Piping Designed/ Installed/ Commissioned to Specified Safe Operating Limits [Design Basis] PC001 Pressure Vessels PC002 Heat Exchangers PC003 Rotating PC005 Hydrocarbon Piping and Piping Designed/ Installed/ Comissioned to Specified Safe Operating Limits (Corrosion Allowance, Material Selection and vessel linings as directed by licensors) PC001 Pressure Vessels PC002 Heat Exchangers PC003 Rotating PC005 Hydrocarbon Piping and Piping Designed/ Installed/ Comissioned to Specified Safe Operating Limits (Coating Integrity) PC001 Pressure Vessels PC002 Heat Exchangers PC003 Rotating PC005 Hydrocarbon Piping Preventive maintenance of pumps and replacement of seals based on condition of seals PC003 Rotating Area Demarcation between and non- facilities Earthquake/ subsidence Monitoring Control System with operator intervention [Control room operator operates the plant according to standard operating procedures using the information from DCS (SOP)] ER009 Control & Alarms and Piping Operated within Specified Safe Operating Limits PC001 Pressure Vessels PC002 Heat Exchangers PC003 Rotating PC005 Hydrocarbon Piping and Piping Operated within Specified Safe Operating Limits (Corrosion Allowance and Material Selection) PC001 Pressure Vessels PC002 Heat Exchangers PC003 Rotating PC005 Hydrocarbon Piping and Piping Operated within Specified Safe Operating Limits (Coating Integrity) PC001 Pressure Vessels PC002 Heat Exchangers PC003 Rotating PC005 Hydrocarbon Piping Flange Management Program Main/Plant Roads Integrity as per Specification Structural Integrity SI001 Structures Structure design according to BOD and seismic activities specifications Structural Integrity SI001 Structures Instrument Protective Function, Instrumented Protection System and Shutdown (ESD) Shutdown SD001 Shutdown (ESD) Control System Monitoring Control System with operator intervention [Control room operator operates the plant according to standard operating procedures using the information from DCS (SOP)] ER009 Control & Alarms Corrosion Protection System (N2 blanketing of V-301) Insulating gasket between dissimilar materials All flange are fitted with inner ring, spiral wound gasket PC005 Hydrocarbon Piping Safety distance between roads and process equipment Pile and foundation integrity Structural Integrity SI001 Structures Overpressure Protection System and Relief System PC007 Relief System (PRV, PSV, etc) Understand hazards Identify Safety Critical Elements Instrument Protective Function, Instrumented Protection System and Shutdown (ESD) Shutdown SD001 Shutdown (ESD) Control System Corrosion Monitoring and RBI Identify Safety Critical Tasks Capture actions and recommendations Corrosion Monitoring and RBI Periodic statutory inspection of pressure vessels All vehicle movements in process areas are subjected to permit to work system or controlled by procedures if routine Piping design to allow flexibility during earthquake activities PC005 Hydrocarbon Piping 01.03 LPGs (e.g. C3/C4 cuts, Raffinate 1, 2 & 3) RAPID SCCU Facilities: Loss of - U3420 MTBE - L a Control of Ignition sources (e.g. Earthing and Bonding, Vehicle/ Spark Arrestors, Thermal Insulation for high temperature explosed surfaces) Ignition Control IC003 Certified Electrical IC005 Electrical Earthing Continuity (Earth Bonding) IC008 Miscellaneous Ignition Control Components SI005 Road vehicles Hazardous Area Classification Flame/Flammable Gas Detectors to initiate Alarms with operator to verify and initiate shutdown if appropriate Detection DS001 Fire & Gas Detection Operational control of ignition sources (e.g. Hot Work Permit, Vehicle entry restrictions etc) Detection by field operator and use of Manual Call Points with operator acknowledgement (no detection equipment) ER004 Communication Ignition Control: Lightning protection system for buildings and tall structures (e.g.telecommuni cation Tower, flare stack, columns) as per IEC requirement Ignition Control IC005 Electrical Earthing Continuity (Earth Bonding) Shutdown System Shutdown SD001 Shutdown (ESD) Control System SD006 Shutdown Valves (ESDV) SD009 Utility Air Flame/Flammable Gas Detectors to initiate Alarms with operator to verify and initiate shutdown if appropriate Detection DS001 Fire & Gas Detection Centralized Fire Services (CEFS) and external agencies response team Detection by field operator and use of Manual Call Points with operator acknowledgement (no detection equipment) ER004 Communication Power System and UPS ER005 Uninterruptable Power Supply (UPS) ER007 Power Shutdown System ALARP demonstration Shutdown SD001 Shutdown (ESD) Control System SD006 Shutdown Valves (ESDV) SD009 Utility Air Spill and Accidential Chemical (ACC) Drainage System ER010 Bunding and Drains (Hazardous and Non-hazardous) Passive Fire Protection System (Fire proofing for steel structures supporting HC vessels and piperacks) Protection PS006 Passive Fire Protection Waste Water Treatment facilities Firewater Spray System (including Ring Main/Other Distribution System, Deluge valves and Water Spray System) Protection PS001 Deluge PS005 Firewater Ringmain and Other Distribution PS009 Sprinkler Environmental Impact Manual/Portable Firefighting operated by MTBE emergency response team (including fire hydrants, fire water monitors, mobile foam cart) ER008 Manual Fire Fighting Centralized Fire Services (CEFS) and external agencies response team Power System and UPS ER005 Uninterruptable Power Supply (UPS) ER007 Power Escape evacuation and rescue facilities including escape route, emergency lighting and wind sock ER001 Temporary Refuge/ Primary Muster Areas ER002 Escape & Evacuation Routes ER003 / Escape Lighting telecommunicatio n system (e.g. dedicated hotline, PAGA) ER004 Communication Fire/ explosion escalation mitigated by safety distance between process units and manned populated areas Occupied buildings (OSB) designed for blast load and fire Protection PS002 Explosion Protection including Blast Barriers and Venting Provisions ER001 Temporary Refuge/ Primary Muster Areas Fire/ Explosion/ leading to onsite/ offsite personnel injuries/ fatalities Storm drains system ER010 Bunding and Drains (Hazardous and Non-hazardous) Plant Design according to BOD and Environmental Loads Specifications ER010 Bunding and Drains (Hazardous and Non-hazardous) Climate Extremes (eg Heavy Rain, Strong Wind) Lightning Lightning protection system including earthing and bonding for buildings and tall structures as per IEC 62305 (e.g.telecommuni cation Tower, flare stack, columns) Ignition Control IC005 Electrical Earthing Continuity (Earth Bonding) Integrity of Cranes, Mechanical Handling and Appliances Structural Integrity SI003 Heavy Lift Cranes and Mechanical Handling Dedicated Areas with suitable foundation for supporting heavy lifting crane Lifting Activities are strictly controlled by Permit to Work system Dropping/ Swinging Objects Daily visual inspection by field operator Structures and Foundations Operated within Specified Safe Operating Limits Structural Integrity SI001 Structures Structures and foundations Designed/ Constructed to Specified Safe Operating Limits Structural Integrity SI001 Structures Structural failure for process structures, storage tanks and vessel supports (eg fatigue, corrosion, human error etc) Entire system is air free using N2 before introducing hydrocarbons Ignition Control IC007 Inert Gas Internal explosion inside vessel during start-up Catalyst changing activities Steam purge of reactor before opening to atmosphere 10
Communicating hazard management Bowtie diagrams have many different uses: Senior Leaders High-level overview Conversation-starter for site visits Context for process safety KPI Workforce Hazard overview Operational risk assessment Permit risk assessment 11
Bowtie use in various industries "Bowtie is one of many barrier risk models available to assist the identification and management of risk and it is this particular model we have found (and are still finding) useful". We are improving our risk management process through the objective centred bow tie approach. 12 ERM is also using bowties with clients in: Food production Manufacturing Road transport Upstream O&G Downstream O&G Chemicals
MR9 Using Bowties in Safety Auditing MR10 Bowties provide all information necessary to develop a focussed audit protocol
Slide 13 MR9 This slide should show how bowtioes meet the requirements of the previous slide Martyn Ramsden, 05/05/2016 MR10 Don't understand thsi graphic Martyn Ramsden, 05/05/2016
Using bowties For each barrier on a bowtie Does it actually exist? Is there evidence of a maintenance program? Is the responsible person competent? Is it appropriate for the hazard Is it in good order? 14
Typical application Techniques typically applied to: Large organisations with many sites having similar hazards Single sites with a range of hazards Sites which are at an early stage of process safety maturity May have generic bowties for large organisations Generic bowties must be made local what s different here? May need to develop bowties where none exist Hazard Identification Develop bowties for a couple of hazards Developing bowties in a workshop is the first part of the audit! Gaps or deficiencies often become apparent without even looking at the site. 15
Typical application HAZID and bowtie workshop Provides insight to audit team to identify areas to investigate further Takes site team on a journey of discovery, rather than just presenting findings Bowtie is useful for site to use in training and for raising process safety awareness 16 Audit process split between safety safeguards equipment and tasks Management systems E.g. MoC, PTW
Audit output Findings around: Control strategy Have you got the right controls? Overall control effectiveness Do the controls actually work? Do people know what they have to do to make controls effectiveness? Management systems Do these support the effectiveness of controls? Greater understanding of process safety hazards and the measures necessary to manage them effectively 17
Typical Site Audit 4-5 days 2.5 days 2 days
Advantages of method Focussed: On those systems, tasks and equipment of direct importance to managing process Flexible: To allow the auditor to follow areas of particular concern at each site Educative: Allows sites to understand why findings are important and the potential outcomes of weaknesses 19
Application of method ERM engaged in major program with manufacturing organization Sites on all continents Variety of hazards Differing levels of maturity Successful program delivering Understanding of process safety issues across portfolio Increased process safety awareness across sites 20
Available guidance on bowties 21
Questions