Asset IntegrItyProcess sAfetyVisible Leadership Questions

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tAble of contentsGuidance for effective visible leadership conversations 3

Leadership 4 Leadership and assurance 5

Risk management 6 Process Safety competence 7 Managing risk / documented demonstration of ALARP/ 8

HSE case/HEMP Management of Change (MOC) 10 Contractor management 11

Design and Construct 12 Design and engineering standards 13

Operate 14 Operating procedures 15 Permit to work 16 Emergency response 17

Maintain and inspect 18 Maintenance and inspection management processes 19

This document is a resource to assist leaders to have quality conversations with staff about Asset Integrity-Process Safety Management (AI-PSM).

Basic guidance and questions for Visible Leadership in HSSE are included in the Guide for Visible Safety Leadership. This document provides more detailed questions for conversations about Asset Integrity Process Safety Management (AI-PSM) barriers.

The same format is used, providing questions for self reflection and

questions to ask others.

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tAble of contents guIdAnce for effectIve vIsIble leAdershIP conversAtIons

1 Prepare! Speak with the asset manager of the site in advance of your visit to establish what to focus on. Understand the key challenges of the facility, the requirements, and which questions to ask.

2 As an asset manager use the questions as a guide to vary the topics of conversation, covering a variety of aspects making up AI-PSM.

3 Use the questions as the basis for a conversation, not a checklist! Dont try to cover all areas.

4 When uncertain about the response received, follow up with a subject matter expert.

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leAdershIP

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leAdershIP & AssurAnce

reflect self Do I focus on major AI-PS Hazards? How do I ensure I am delivering consistent AI-PS messages and objectives to my staff and contractors? Are my engagements with front-line staff effective? Do I seek feedback?

Do I include Process Safety discussions/topics in my regular stakeholder engagement sessions with Shell staff, contractors, neighbours, etc.?

Am I aware of how I am perceived by the organisation and take action accordingly?

How do I know that my asset is fit to commence or continue operations? Am I regularly reviewing leading and lagging Process Safety KPIs? Am I challenging the greens and supporting the reds. Do I welcome bad news?

Ask others

What is the general understanding and awareness of Process Safety? Can you give an example where activities were stopped to reduce Process Safety risk?

Are you empowered to intervene and stop operations when notsafe? How are local managers, and supervisors visible in the field, engaging with staff about AI-PSM?

Which operations give you a feeling of unease and why? Are facilities in support of managing Process Safety addressed adequately when failing?

How do you incorporate learning from Process Safety incidents and audits into procedures, work processes and training programs?

Are safeguarding events (e.g. alarms, emergency shutdown systems and relief valves triggered) reported and followed up as near misses?

Have you implemented the Statement of Fitness (to be completed for all assets prior to startup following construction or significant maintenance)? Can you show me an example?

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rIsk MAnAgeMent

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Process sAfety coMPetence

reflect self Do I participate in some type of Process Safety related investigation/review every 1-2 years?

Who are the people with HSSE critical roles and how do I know they are competent?

Have I closed my HSSE competence gaps? (Shell Open University modules Manage HSSE Risks Lead/Prepare/Apply)

Do I need more knowledge on key Process Safety barriers, e.g. HEMP, Management of Change (MOC), Permit to Work (PTW), Design Standards, Asset Management Processes, Emergency Response, Overrides management, Statement of fitness?

Ask others

Have you/staff on your site completed the assigned Management of Change (MOC) training?

Have you/staff on your site attended a Barrier Thinking Training session?

Are Process Safety relevant competence development programs on track (Fire fighting, PtW, shore officer certification, etc.)?

Is Process Safety management specifically addressed in yourGPA?

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reflect self Do I know whether the documented demonstration of ALARP HSE case is current?

What are the key risks addressed in the HSE case and do I manage them?

What are the significant process safety risks for my area or operational responsibilities? Consider PSBRs (tank overfilling etc.), operational interfaces ( truck/rail/vessel loading etc.), interconnections (pipeline failure, supporting third-party activities etc.).

How do I know that my key process safety barriers are functioning? Do I understand the overall HEMP process, the application of ALARP (As Low as Reasonable Practicable), and my approval role in HEMP?

Until what extend do Bowties or equivalent play a role in my asset to manage high risks?

Do I ensure annual reviews, focusing on Process Safety management, take place for my area of responsibility?

MAnAgIng rIsk/docuMented deMonstrAtIon of AlArP/hse cAse/heMP

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Ask others What is your role in maintaining effective AI-PSM barriers? What are the hazards here and what could happen if theyre realised?

In your view, what are the critical process safety activities, and which ones could be improved?

Do you feel that certain activities affecting process safety get too little attention?

Do you believe we consistently apply risk rating to assets? Has a HEMP analysis been completed for your site? If so, what were the main conclusions?

Does the HSE case feature as part of your personal knowledge to manage Process Safety?

Are ALARP decisions which balance Process Safety risk and economics explained ?

MAnAgIng rIsk/docuMented deMonstrAtIon of AlArP/hse cAse/heMP

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MAnAgeMent of chAnge (Moc)

reflect self How do I know that key process safety barriers are effective, specifically management of change?

Do I ask questions about all three types of MoC; procedural, organizational and hardware/technical?

How am I involved in reviewing MOCs and MOC registers? How do I manage emergency and temporary MOCs?

Ask others

What was the last MOC you were involved in? How do you ensure MOCs are raised for all relevant changes? Can you explain/show me the procedure for emergency and temporary MOCs?

How do you ensure quality and consistency of the MOC? How are open MOCs and the MOC register monitored? Is documentation properly updated as part of change management?

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reflect self How do I ensure that my engagements with staff involve contractors? How do I know that for work in my sites the right contractors are selected, and that their work is adequately monitored and supervised?

Ask others Who is accountable for contractor safety on your site? How are contractor staff involved in engagements about safe working on site?

Which are the high risk contracts related to AI-PSM and who are the contract holders? How competent are these contract holders and what support do they get from CP or HSSE?

How are contractors informed of their potential impact on future Process Safety incidents?

contrActor MAnAgeMent

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desIgn And construct

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desIgn And construct

desIgn And engIneerIng stAndArds

reflect self How do I know that the appropriate engineering standards (Design Engineering Manual 1) are applied for projects in my area?

How do I know that Process Safety basic requirements (Design Engineering Manual 2) are applied in my assets?

When was my last PSR? How do I ensure proper definition of follow up and close out of actions?

Do I use Process Safety start up reviews before commissioning projects and plant changes, after turnarounds and after trips where the design conditions may have been exceeded?

Ask others

What engineering standards do you apply for this facility (or project) and who are your Technical Authorities that can approve derogations to standards?

Are technical standards known at site level? How do you ensure that the HSSE requirements in project guides 1 (HSSE & SP management) and 14 (Operations Readiness) are followed?

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oPerAte

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oPerAtIng Procedures

reflect self How do I know that my key process safety barriers are functioning, specifically within operational limits?

Do I know the number of alarms/hr that come into your control rooms and how effectively we are dealing with them?

Do I know how operations manuals are used in my assets and the effectiveness thereof?

Ask others How do you manage your operational alarms and any overrides to safeguarding systems? How many overdue overrides do you have?

How is self assessment on operating procedure done on this site, specifically regarding shift handovers of ongoing activities (product/tank transfers, abnormal operations etc.)?

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PerMIt to Work

reflect self How do I know that my staff, especially permit issuers and gas testers, have the required competences?

Do I check compliance with work permits during safety walks?

Ask others How do you check work permits to review that control and recovery barriers are correctly and sufficiently included? How many work permits are spot checked per year to identify learnings?

How do you file completed work permits? How are workers informed of the permit requirements?

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reflect self What expectation do I have of my staffs involvement in Emergency Response on site?

How do I know that resources (equipment, staff, external resources) are maintained/trained and ready to be deployed when needed as documented in the Emergency Response Plan?

Ask others What are your (Medical) Emergency response plans and how often do you test them?

When was your last Emergency Response drill? What was it about? What did you learn?

Do Emergency Response drills involve external stakeholders and do they address the highest risk scenarios?

eMergency resPonse

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MAIntAIn And InsPect

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MAIntenAnce And InsPectIon MAnAgeMent Processes

reflect self How do I exercise visible leadership in the field regarding Maintenance and Inspection Management?

How do I know that my key Process Safety barriers are functioning and technical integrity is being maintained?

How do I know the organisation is complying to the maintenance system requirements, both in terms of resources and competences?

Do I have overdue inspections? How do I manage these? How do I deal with extended inspection interval (derogation, mitigation plans)?

Ask others

Who is the Asset Owner, Asset Operator and Asset Integrity Manager for this plant? How does segregation of duties apply to the Asset Integrity process?

What is the general state of your assets? Which are the key challenges? Can you briefly describe the Reliability & Integrity (R&I) Plan for the assets? What are the safety critical equipment for this plant? Do they have performance standards? Are there any work orders overdue associated with them in the last year? Do you regularly perform Asset Management System Reviews? What were the key outcomes of the last one for this plant?

How are non compliances addressed? Can you tell me about (recent) corrosion and leak incidents, and how they have been resolved?

Can you tell me of any equipment break downs recently and why this occurred? Was there any impact to business?

How do you assure that all agreed integrity and maintenance action items are implemented?

How you deal with extended inspection interval (derogation, mitigation plans)?

How do you manage Integrity and maintenance documentation?

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If more detail is required, further questions can be found in the relevant Self Assessment documents collected in the PS leadership toolkit (e.g. Group HSSE & SP Control Framework Assurance Protocols, S&D Process Safety Self Assessment Toolkit, S&D Asset Management System HealthCheck).

Suggested reading: Management Walk-Arounds: Lessons from the Gulf of Mexico Oil Well Blowout by Professor Andrew Hopkins, Australian National University [available in the Process Safety GDT leadership toolkit].