8/2/2019 115417 HSE in Design

1/16

HSE in DesignBest Practice Forum July 2007

8/2/2019 115417 HSE in Design

2/16

HSE in Design

Anonymous quote from a fitter Bass Strait

If you want something simple,made ##### difficult get an

engineer involved!!

TheKnack-_Harris.mpg

8/2/2019 115417 HSE in Design

3/16

HSE in Design

What does the term HSE in design mean to us?

The technical side of HSE (using sophisticated tools(rightly) for managing the risks in design)

QRA, EIA,HAZOP, HAZID,ENVID,HEMP, SIL standard tools supported by software programmes usedfor achieving statutory compliance and design safety

intent however not used throughout industry sectors! On the other hand the more agricultural aspect of HSE

e,g, field execution rely on PPE and JHAs etc.

8/2/2019 115417 HSE in Design

4/16

HSE in Design

Sharp EndSharp EndFront EndFront End

What is happeninghere?

Event

CurrentFocus

JHA, JSA

Stepback 5x5

PPE, BOPs

Just Culture

PTW

Challenger;Piper

Alpha;

Texas City;

Bhopal.

8/2/2019 115417 HSE in Design

5/16

HSE in Design

The events are memorable and often lead torecommendations/statutes on design requirements

Piper AlphaPiper Alpha

Texas CityTexas City

8/2/2019 115417 HSE in Design

6/16

HSE in Design

The fact is that many accidents occur related to designissues they dont make headlines, dont get fed backinto the organisation and therefore dont provide impetusfor change

This presentation illustrates several examples, onewhere a design feature failed and one where a designspecification was not included

It will also give some thought on the transition fromengineering to Construction and where areas of risks

can occur

8/2/2019 115417 HSE in Design

7/16

Case Study Field Engineering

Erection of Structural Steel

Design intent was to hold the gratings in by welded

brackets - fitted during fabrication An added safety feature to secure the grating prior to

clipping

8/2/2019 115417 HSE in Design

8/16

Case Study

As the structure was torqued up what happened?

The Gratings rode over the bracket and created agreater hazard!

What was the decision made at that time?

Back to basic and not fit the brackets

The design caused a deviation from standard workingpractice e.g. Access was allowed/Clips not fitted

8/2/2019 115417 HSE in Design

9/16

Conclusion

Steel erection Foreman allowed pipefitters into the areato string out pipework

He advised them the structure wasnt torqued

He stepped onto a grating which moved and he fell tohis death

There were other factors but the design initiated the

chain of events that led to someones death

8/2/2019 115417 HSE in Design

10/16

2nd study

LNG plant

Specification called for non-return valves to be fitted for charging

the systems

Final design didnt include these valves not ordered

Punch listing by customer identified that the valves were not fitted

Hundreds of valves were ordered and fitted as a priority

Some were sticking

8/2/2019 115417 HSE in Design

11/16

2nd study

Recharging a glycol wet leg system

System (operated at 48 Bars) with valve isolations

Relief valve not operated so couldnt refill against thehead of pressure

Connected to the drain lines (traditional method)

Opened relief valve when he still couldnt charge On completion his Colleague operated the main supply

valve by mistake

The system became pressured and blew the bottom outof the charging can, hitting the technician in the face

8/2/2019 115417 HSE in Design

12/16

HSE in Design

What is common to both incidents?

The engineers responsible will never know

8/2/2019 115417 HSE in Design

13/16

HSE in Design

Engineering exerts a major influence on an EPCMproject

Too much engineering can impact on constructionschedules, creating higher levels of risk (The madscramble)

Field Engineering changes made without theappropriate safety reviews

A word on CDM 1994

8/2/2019 115417 HSE in Design

14/16

Evolution of HSE

T im e

1 9 8 0 s

TECHNOLOGY

1 9 9 0 s

TECHNOLOGY

MANAGEMENT

SYSTEMS

2 0 0 0 +

TECHNOLOGY

MANAGEMENT

SYSTEMS

BEHAVI OUR

Zero ha rm

EngineeringEngineering ConstructionConstruction

8/2/2019 115417 HSE in Design

15/16

Practical Considerations

Preliminary project risk assessment what you aregoing to build, where its going to be built, who is goingto build it and what resources are needed

- Example if scaffolding is a problem, design in the access

Get the engineers into the field, most never see what

they design Hold design reviews and involve the right balance of

people (not just for safety)

Prior to an engineering safety review, take timeout for asafety moment

Have a common project risk register that doesnt stop at

Detailed Design

8/2/2019 115417 HSE in Design

16/16

Conclusion

HSE in design is not just about integrity and reliability ofthe product

It affects the whole project - construction,commissioning and eventual maintenance

The state we want is;

If you want something difficult madesimple, get an engineer