CC & technical support services www.silsupport.com Process Safety Workshop Avoiding Major Accident Hazards the Key to Profitable Operations A two (2) day workshop with many practical methods, case studies and examples based on experience in Europe, Africa, Australia and the USA. Workshop Facilitator: Clive Timms BSc., MPhil., CEng., MIET, TÜV FSExpert. Expert International Functional Safety Engineer Recent events such as the BP Texas City oil refinery disaster and Europe s biggest ever explosion at the UK Buncefield Oil Storage Depot underline the need to identify and assess all hazards to ensure the risks are appropriately managed. Participants will be introduced to the concepts of internationally adopted standards IEC 61508/61511 and the latest tools and techniques for risk assessment and risk management. They will be able to apply their newly acquired knowledge and skills to better manage their process and operational related hazards and associated risks. CAPITALISE ON THE EXPERT KNOWLEDGE AND EXPERIENCE TO AVOID MAJOR ACCIDENT HAZARDS AND MAINTAIN PROFITABLE OPERATIONS Learning how to identify process and operational hazards and the principles of hazard and operability (HAZOP) studies Understanding what represents risk and how to assess safety, asset and environmental risks The requirements of Safety Management Systems and avoiding improvement notices and enforced shutdown by the Regulator The concepts and differences between qualitative and quantitative risk assessment (QRA) methods and when and how to apply them Setting tolerable risk targets for safety, your asst and the environment and methods to achieve these targets Process Safety Workshop Page 1 of 7
How to set up, use and apply the most popular risk assessment methods such as risk graphs, risk matrices and layers of protection analysis (LOPA) The principles of fault tree analysis (FTA) and how to model protective systems using this technique The concept of reducing risks to as low as reasonably possible (ALARP) The use of cost benefit analysis to demonstrate that sufficient risk reduction has been applied The principles and concepts of the internationally agreed standards IEC 61508 and IEC 61511 for safety instrumented systems Learning how to design safety instrumented systems for protecting against process related hazards. Performing calculations such as probability of failure on demand (PFD), safe failure fractions and hardware fault tolerance How to identify and calculate the impact of common cause failures (Beta factor) on the reliability of protective systems The importance of testing and maintaining protective systems and how to calculate the most optimal test and maintenance strategies Introduction to the latest software tools for risk assessment and designing safety instrumented systems and integrating them with other protective technologies Workshop Duration 2 days Workshop Objectives Led by a globally recognised expert in functional safety, this workshop will equip participants with the most popular and internationally adopted methods and tools for identifying and managing the risks associated with their process and operational related hazards. Such hazards can lead to loss of life, damage to their asset, loss of production and profitability, damage to the environment and company reputation. Participants will be introduced to the concepts of the main international standards that cover this area of risk assessment and risk reduction. The topics cover the concepts of identifying hazards, hazard analysis and HAZOP. This will be further developed into the assessment of risk and methods of risk reduction using instrumented systems and other technology. Hazards do not only represent risk in terms of safety, but they can also mean significant incurred losses from production and equipment damage. Company reputation can also be severely compromised if it is exposed to environmental issues and the assessment of environmental impact will also be covered. Process Safety Workshop Page 2 of 7
Both qualitative and quantitative methods for undertaking safety, asset loss and environmental risk assessments will be discussed and applied. The workshop will provide practical guidance on the application of the principles of IEC 61508 Functional safety of electrical/electronic/programmable electronic safety systems and IEC 61511 Functional Safety: Safety Instrumented Systems for the Process Sector. During the second day delegates will be taken through the requirements for a Safety Requirements Specification (SRS) and shown how to undertake appropriate cost effective designs for Safety Instrumented Systems (SIS) and Safety Instrumented Functions (SIF) and how optimal test and maintenance strategies for them can be achieved. You will be shown how to take advantage of the most popular standards to achieve capital expenditure savings and ongoing operational expenditure savings for emergency shutdown and fire and gas systems. Throughout the workshop, emphasis will be placed on experience and realistic practical exercises and case studies will be used to compliment the instruction. Who Should Attend Senior Process Managers and experienced Process Engineers, Instrument Engineers and Safety Engineers, as well as Operating and Maintenance personnel who are responsible for, or involved in any of the lifecycle phases for safeguarding systems from hazard and risk assessment, shut down system/fire and gas systems design through to testing and maintenance. Workshop Program HAZARDS AND ASSOCIATED RISKS Identifying hazards and the principles of HAZOP Safety Management Systems The Safety Life Cycle The principles of ALARP and tolerable risk Risk reduction layers METHODS FOR RISK ASSESSMENT Risk reduction layers Qualitative risk assessment Quantitative risk assessment Fault Tree Analysis (FTA) Risk graphs and matrices and calibration Layers of Protection Analysis (LOPA) Safety Integrity Levels (SIL) SIL determination by qualitative methods SIL determination by quantitative methods Process Safety Workshop Page 3 of 7
RISK REDUCTION METHODS AND SYSTEMS Emergency shutdown systems (ESD) Fire and Gas Systems (F&G) Safety Instrumented Systems (SIS) Safety Instrumented Functions (SIF) Designing SIF and SIS Integrity specification of a SIF Selection of appropriate components and subsystems for SIF/SIS design The concept of proven in use and not proven in use Field devices Initiators, logic solvers and final elements for safety instrumented function HOW TO UNDERTAKE RELIABILITY CALCULATIONS Failures types Failure modes Failure and reliability Demand modes Probability of failure on demand (PFD) SIF implementation for low demand modes IMPORTANCE OF TESTING AND MAINTENANCE Importance of testing Relationship between testing and the probability of failure Importance of maintenance Relationship between maintenance and the probability of failure Fractional dead times Common cause failure and its affect on PFD Safe Failure Fraction Hardware fault tolerance Partial closure testing of valves Measurement validation and comparison Reliability data types, sources and conversions Note: Practical exercises will performed throughout the course. Syndicate exercises will be undertaken in groups of four All exercises will be taken from real life examples. Process Safety Workshop Page 4 of 7
About Your Workshop Facilitator Mr. Clive Timms has over 38 years experience in the petrochemical industry with offshore and onshore plants experience. He retired from Shell UK Exploration and Production in 2001 where he was Head of Automation and Control. He is now a Director of C & C Technical Support Services Limited which specialise in the application of and training for the IEC 61508 and IEC 61511 standards. He chaired the UKOOA working group that produced the UKOOA Guidelines for Instrumentbased Protective Systems, as an offshore sector interpretation of IEC 61508. He is a Chartered Engineer with a BSc. and MPhil in Control Engineering, and is a Member of the IEE and a TÜV FS Expert. He currently chairs the Institute of Measurement and Control Safety Panel. 1. Head of Automation and Control for Shell UK Exploration and Production The Technical Authority for all instrumentation and control matters for all UK offshore North Sea operations and onshore plants. Responsible for authoring numerous Shell standards and mentoring and developing I&C engineers. 2. Technical Authority for the Shell Expro Northern Business Unit The automation and control technical authority for the Cormorant Alpha, Dunlin, North Cormorant, Tern and Eider offshore platforms in the UK northern North Sea sector. 3. Chairman of the UKOOA Instrumentation and Control Group Chair of the UK Offshore Oil Operators Association s team that developed the UKOOA Guidelines for Safety Instrumented Systems. The first sector specific guidance on the application of the international IEC 61508 standard for safety instrumented systems. 4. Current Chairman of the Institute of Measurement and Control Safety Panel The Safety Panel represents the opinion and interests of functional safety by organising and holding workshops and conferences on safety instrumented related topics, and acting as a UK focal point for the ongoing maintenance and development of IEC 61508 and associated standards. 5. Functional Safety Consultant to the UK HSE Buncefield Working Group 5 Functional Safety Consultant with the UK HSE Working Group 5 to advise on and demonstrate risk reduction methods such as layers of Protection analysis following the Buncefield Tank farm explosion. 6. Consultant Functional Safety Expert to Total UK Providing training and expert advice on functional safety and acting on behalf of Total in meetings with the UK HSE Regulator. Undertaking SIL determination and SIF design calculations and facilitating various studies including the protective systems for the Buncefield pumping station at their Lindsey Oil Refinery. Process Safety Workshop Page 5 of 7
7. Functional Safety Expert Consultancy to Woodside Offshore Petroleum, Australia Consultant Functional Safety expert to Goodwyn Safety Systems Upgrade project to audit and assess compliance with international standards and regulatory requirements for replacement emergency shutdown and fire and gas systems. 8. Consultant for Functional Safety to ChevronTexaco Houston, USA Consultant for functional safety for chairing SIL determination studies for their Benguela Belize, Lacula and Tacula offshore and onshore West African facilities. 9. Consultant for Functional Safety to Honeywell at MOL Refinery Hungary Functional Safety Consultant to Honeywell Hungary for the purpose of validating the SIF design and partial valve closure testing calculations for a new shutdown system at the MOL BEK Refinery in Hungary. 10. Consultant for Functional Safety to Honeywell at Arpechim Refinaery Romania Functional Safety Consultant to Honeywell Romania for the purpose of undertaking a SIL determination exercise for the whole of the OMV Arpechim refinery in Romania. 11. Consultant for Functional Safety to ABS Consulting Kuwait Functional Safety Expert consultant to validate safety instrumented system designs for a number of the Kuwait Oil Company onshore and offshore facilities. 12. Consultant for Functional Safety to Millennium Chemicals UK Functional Safety Expert to Millennium Chemical in the UK for writing functional safety standards, chairing SIL determination exercises and undertaking SIS design calculations. 13. Functional Safety Consultant for Maersk Janice Facility Alarm Review Developing alarm strategy and configuration standards and the facilitation of an alarm review and rationalisation project for the Maersk Janice offshore platform in the UK North Sea. 14. TÜV Certified Functional Safety Expert Clive is a TÜV Certified Functional Safety Expert and trainer for the TÜV FS Engineer certification scheme. 15. Publications Include: A Methodology for Alarm Classification and Prioritisation IEE: People in Control, June 1999. IEC 61508 is it Pain or Gain? Measurement & Control, Volume 35, July 2002. IEC 61508/61511- Pain or Gain American Institute of Chemical Engineers: Process Safety Progress (Vol. 22 No. 2) June 2003. IEC 61511- an aid to COMAH and Safety Case Regulations compliance IEE: IEC 61511 Roll-Out Seminar December 2003 Process Safety Workshop Page 6 of 7
. How to Achieve 90% of the Gain Without Too Much Pain. Measurement & Control, Volume 37/1, February 2004. Determination of Safety Integrity Levels Taking Into Account ALARP- Cost Benefit Analysis IChemE: Hazards XIX, March 2006. Software Tools for the Lifecycle Support of Safety Instrumented Systems Measurement & Control, Volume 39/10, December 2006. Climbing the Alarm Mountain Safety Control Systems Conference, Brisbane, Australia, November 2006. Achieving ALARP with Safety Instrumented Systems Measurement & Control, Volume 39/10, December 2006. Hazards Equal Trips or Alarms or Both IChemE Process Safety and Environmental Protection, Volume 87 January 2009 Prices: From 1,000 GBP (Euro 1,000) per participant. Contact: Clive Timms, Tel: +44 (0) 1339 886618, Email: c.timms@ifb.co.uk Website: www.silsupport.com Process Safety Workshop Page 7 of 7