PROCESS SAFETY - BARRIER MANAGEMENT - AIChE

PROCESS SAFETY – BARRIER MANAGEMENT Nageswara Rao HSSE Manager Shell Technology Center Bangalore Copyright of Shell Technology Centre Ba nga lore RESTRICTED 1

O u r a ssets a r e Sa f e a n d w e k n o w it Copyright of Shell Technology Centre Bangalore RESTRICTED

WHAT IS A BARRIER? Ba rriers a re mea sures tha t reduce the proba bility of relea sing a ha za rd, a nd reducing the consequence of a relea sed ha za rd Ba rriers ca n be ha rdwa re, huma n intervention, or a combina tion Two types of Barriers Control BarriersReduce likelihood (pro-a ctive/ preventa tive) e.g. High Pressure a la rm/ opera tor response; Automa tic high pressure interlock; Pressure relief va lve Recovery BarriersMitiga te consequences (re-a ctive), e.g. Ga s detection a la rm / opera tor response; a utoma tic sprinkler system, emergency response Copyright of Shell Technology Centre Bangalore RESTRICTED June 2013 3

Bo w -Tie a p p r o a ch to m a n a g e sa f ety Bow tie : It is a gra phica l representa tion of threa ts & potentia l consequences rela ting to a ha za rd, a nd the ba rriers. Step 5 Step 5 Step 1 H A Z A R D Recovery Measures Step 4 Controls Threat 1 Threat 2 Step 3 Step 2 Consequence 1 Top Event Consequence 2 Consequence 3 Threat 3 HSSE Critical Activities List of HSSE Critical Equipment HSSE Critical Processes Copyright of Royal Dutch Shell PLC Step 6 Confidential 4

EXAMPLE - LION AT THE ZOO Hazard Lion Control Barriers Threat Top Event Human Error; Materials of Const.; Loss of Control; Improper cage design etc. Zoo Keeper Rounds etc. Lion gets out Copyright of Shell Technology Centre Bangalore Recovery Measures Zoo Emergency Response Plan RESTRICTED Consequences Injuries, Fatalities

EXAMPLE - VEHICLE ACCIDENT Sta te Inspection Driver inspections Preventive Ma intena nce Loss of Control Sta te Inspection Driver inspections Preventive Ma intena nce Corrective Ma intena nce Vehicle not a dequa tely ma inta ined Copyright of Shell Technology Centre Bangalore Instrument/ wiring fa ilure Sa fety Equipment (a irba g, ABS, sea tbelts) Instruments/ wa rning Devices Vehicle Mecha nica l Fa ilure Design HAZARD- Road Transportation Threats- driver impa irment/ distra ction, tire fa ilure, mecha nica l fa ilure, wrong vehicle, etc. Rules a nd Regula tions Sta te Inspection Ma nufa cturer’s Requirements Tra ining Not a va ila ble or not used RESTRICTED Collision/ Injury

PROCESS EXAMPLE - BARRIER BASICS Exa mples of Control a nd Recovery Ba rriers Ca n you think of other potentia l Ba rriers? Design H2S Over pressure Inspection PSV Sensor Ala rms Copyright of Shell Technology Centre Bangalore Injury LOPC (Leak) Emergency Response RESTRICTED

BARRIERS – DEPENDENT AND INDEPENDENT Control Control Control Pressure Relief Valve High Pressure Alarm Threat Overpressure This is an Independent and Valid barrier Recovery Measure Loss of Control Gas Detection Recovery Measure Operator Response Operator Response These two barriers together make one Independent and Valid barrier Recovery Measure Recovery Measure Deluge System Emergency Response Consequence Rupture causing Fire, explosion/ fatalities These three barriers together make one independent valid barrier Copyright of Shell Technology Centre Bangalore Loss of Control RESTRICTED

BARRIER VALIDITY CRITERIA Effective Strong Enough/ Fa st Enough a nd Big enough Active ba rriers ha ve to ha ve a sensor, Logic a nd Actua tor Independent Not dependent on a ny other ba rrier Not ha ving a common sensor or logic in common with a nother ba rrier Not rela ted to the threa t Audita ble Being ma inta ined / inspected (CA a nd responsible pa rty) to “gua ra ntee” the PFD ta ken into a ccount Ha ve a PFD 0.1 (ba rrier counting) Copyright of Shell Technology Centre Bangalore RESTRICTED June 2013 9

PERSONAL SAFETY VS PROCESS SAFETY The Lion – Personal Safety Hunts in groups Is often visible (a udible etc ) Commonly seen in its own environment Is a killer Ca n never be fully ta med Ca n never be left ungua rded Needs consta nt vigila nce The Tiger –Process Safety Hunts alone Is secretive a nd ha rd to detect Not commonly seen Is a killer Ca n never be fully ta med Ca n never be left ungua rded Needs consta nt vigila nce Copyright of Shell Technology Centre Bangalore RESTRICTED

RAISING PROCESS SAFETY EMPHASIS AND PERFORMANCE Goal Zero ? Personal Safety Copyright of Shell Technology Centre Bangalore ? ? Process Safety RESTRICTED ?

PERFORMANCE STEP CHANGE NEEDED Goal Zero Personal Safety Process Safety Everyone on the Pitch Increased Focus and Urgency Copyright of Shell Technology Centre Bangalore RESTRICTED

Leadership Action - Be mindful of HSSE risks Demonstrate wariness/ chronic unease Know the main hazards in an operation – if you don't - ask Engage with those doing the work – “ what could go wrong, and what controls are in place to prevent it?” Welcome bad news – “what do you not want to tell me” - a nd rea ct a ppropria tely Watch traffic light reporting – challenge the greens and support the reds

Let us get Barrier thinking to be part of the way we do our work everyday to ensure we prevent major process safety incidents in our business. Yes O u r a ssets a r e sa f e a n d w e k n o w it Copyright of Shell Technology Centre Bangalore RESTRICTED

Tha nk you for Active listening! Copyright of Shell Technology Centre Bangalore RESTRICTED June 2013 15

Active barriers have to have a sensor, Logic and Actuator Independent Not dependent on any other barrier Not having a common sensor or logic in common with another barrier Not rela ted to the threa t Auditable Being maintained / inspected (CA and responsible party) to "guarantee" the PFD taken into account