Safety CourseSafety CoursePart 1Part 1-- Basic notion of HSEMS Basic notion of HSEMS
Safety Concept, HSE Philosophy, HSE PlanSafety Concept, HSE Philosophy, HSE Plan
Made by: Dr Made by: Dr FabienneFabienne SalimiSalimi
Safety Concept Safety Concept
Beginning of ProjectBeginning of Project
Plant Area
SMAG Gas Treating PlantGas Treatment
Plant
Block DiagramBlock Diagram
Plot PlanPlot Plan
Process Flow DiagramProcess Flow Diagram
Hazardous MaterialHazardous Material
Type of MaterialCAMEOWISER
HazardsFlammableToxic
PhaseLiquid Pool fireGas Jet Fire2 phase flow Pool & Jet Fire
PressureAtmosphericPressurisedUnder Vacuum
Major Accident HazardMajor Accident Hazard
An occurrence resulting from uncontrolled developments in the course of the operation of any onshore establishment or pipeline or offshore installation, and leading to serious danger to human health or the environment, immediate or delayed, inside or outside the onshore establishment or offshore installation, and involving one or more dangerous substances.
This includes in particular a major:EmissionFire Explosion.
Design failures External events
Falling objects
Collision / bumping
Release during maintenance
(disassembling)
Physical degradation
(againg-wear out)
Corrosion / errosion
Fatigue / viberation
Overflow / overfilling
Latent failure introduced during
maintenance
Operational failure during normal
production
Process Upsets
Release of hydrocarbons (Loss of Containment)
Overpressure
Operational failures
Technical / Physical failures
OROROROR
OR
Loss of Containment
Direct causes of hydrocarbon releases
Credible ScenariosCredible Scenarios
Major Accident Hazard TreeMajor Accident Hazard Tree
From API 14JFrom API 14J
Vessel Overflow
Equipment Failure
Opening a closed system
Vent/flare system discharge
• Inflow exceeds outflow
• Overpressure*• Leak: Corrosion, Erosion,
Maintenance• Excessive temperature*• Hit by object• Material; quality• Sudden failure of
mechanical seal*
• Valve operation
• Inadequate scrubber size
• Scrubber inflow exceeds outflow*
Oil Spill Escaping gas
Air Pollution
Inadequate drain system
Water pollution
Air Pollution
Asphyxiation/ poisoningInjury
Oxygen xxxx
Fuel
Ignition Source
• Lightning• Static electricity• Electrical short• Electrical sparks• Human induced
• Flashback• Hot surfaces• Exhaust sparks• Open flame • Fire tube
Electric shock
• Lightning• Electrical short• Inadequate
ground• Exposed live
connections
Physical impact
• Fall• Tripping• Slip on slick
surfaces• Hit by object• Overpressure• Cranes• Boats• helicopter
Large fire
• Insufficient or inoperable fire fighting equipment
• Wrong location of F/F equipment
• Inability of shut off fuel
• Lack of adequate warning
Asphyxiation/ poisoning
• Gas leak in confined space
• Leak of toxic chemicals
• Discharge of fire extinguishing agent in confined space
• Smoke from fire
Burns shock
• Hot surfaces• Flare radiation• Burning fluids
Inability to escape
• Blocked escape route• Insufficient lighting• Inappropriate survival
capsule design or location• Lack of fire barriers• Lack of adequate warning• Lack of communications• Lack of visibility• Inadequate training
Injury* Sources which can be anticipated by
sensing charges in process conditions
Fire Explosion
Facilities Features
Practices, System or Equipment Prevent Fluid Release
Prevent Ignition
Prevent Fire Escalation
Provide for Personnel Escape
Hazards Analysis and Risk Assessment X X X X
Equipment Designs per Codes and Standards X X X
Fabrication QA/QC X X
Equipment Protection X
Equipment Maintenance X X X
Surface Safety System X X X X
Drain Systems X X X
Operating Procedures X X
ESD System X X X
Relief System X
Ventilation X
Hot Surface Insulation X
Gas Detection System X X
Separation of Fuel and Ignition Sources X X
Equipment Blowdown X X
Fire Detection System X X
Fireproofing X X
Cooling system X X
Blast walls X X
Fire Fighting X X
Firewalls X X
Personnel Protection Devices X X
Emergency Procedures X X
Escape Routes X
Escape Mechanisms X
Communication System X X
Muster Areas X
Primary Safety Purposes
Hierarchy of Safety Critical BarriersHierarchy of Safety Critical Barriers
Gas Release
Continuous ImprovementContinuous Improvement
Today
Suitable Software
Suitable Software
In 5 Years
Flaws in a safety barrier can be:- Eliminated- Improved by more advanced technology.
HSE Philosophy HSE Philosophy
Safety Distance & Layout Safety Distance & Layout
CRITERIA REF.
Mitigation
API 14J
Table A.1 to A.4
Table A.5
Not SatisfactoryAdd Physical protection
SatisfactoryCoarse QRA Optimisation
Not SatisfactoryAdd Physical protection
Satisfactory
Detailed QRA Checking
Selection of the General Arrangement
Choice of a location
EQUIPMENT LAYOUT
Selection of the Layout of the Installation
Interconnecting the Units
Particular Studies Location of Rooms, Integrated Platforms, Temperory facilities, Future extensions
Fire Zones (FZ)
Units
Definition of the Restricted Area (RA)
Splitting into
Sorting into Separate fuel sources and ignition sources
Logestics, Operability, Environment, Mitigation,
Safety to life
% LFL, Toxicity, Thermal Radiation,
Overpressure
GENERAL ARRANGEMENT
Contigency Plan
Selection of the location
Prescriptive Distance Tables
Update by Consequence Modeling
Spacing between Units
Arrangement of the Units
LOCATION OF THE
Minimise impact from/to the other parties
Choice of a location
Definition of the Impact Area (IA)Layout Methodology
Office
General Service Area
Non-Hazardous Area
Safety Fence
Main Access & Exit
Security Check point
Security fence
Property Limits
Plant Area
Area Under Control
Security Check point
Restricted Area
Hazardous Area
Zone 1
Zone 2
Emergency Exit Secondary Access
Impacted area boundaries
General Services area:OfficeWorkshopWarehouseParking
Plant area:PlantLoading/Unloading HC
Notes:Impact Area extending beyond Property limits or Security fence should be limited or avoidedSecurity fence extending beyond Property limits should be avoided or limitedRestricted Area extending beyond Safety fence in General Service Area, or beyond property limits, should be avoided or limited
Impact, Restrict area and Fire Zones
Typical Plant General Layout
1.5 m
1.5 mFire zone boundary
1.5 m
1.5 mFire zone boundary
15 m or (15.9 kW/m2 & 0.3 bar)
Fire Zone 1(Receiving facilities)
Fire Zone 1(Receiving facilities)
Fire Zone 2(Process)
Fire Zone 2(Process)
IN To Flare OUT
BDV
ESDVProcess ESDV
Receiving facility
ESDVOutlet
ESDVInlet
Possible
Fire Zone 1(Receiving facilities)
Fire Zone 1(Receiving facilities)
Fire Zone 2(Process)
Fire Zone 2(Process)
IN OUTESDV
Inter F-Z
ESDVESDV
Ideal
Fire Zones
Group Type Main equipment Main Hazard
T1 Well-Head Well-Heads, chokes, manifolds, headers Fuel source
T2 Unfired Process
Manifold and headers, separators, gas sales station, heat exchangers, water treatment, pumps, compressors, unit enclosures, finger type slug catcher.
Fuel source
T3 HC storage Storage tanks, sump tanks, produced water- treating tanks. Fuel source
T4 Fired process Fired equipment, line heaters, TEG reboilers Ignition source
T5 MachineryGenerators, electric equipment, air compressors, engines, turbines, technical buildings
Ignition source
T6 Buildings Living quarters, maintenance area and buildings, sewage disposal, water makers Ignition source
T7 Pipelines & Risers Pipelines, Risers, pig launchers, pig traps Fuel source
T8 Vents Fuel source
T9 Flares Including burn pits. Ignition source
Hazards associated with equipment group
Unit Compatibility T1 T2 T3 T4 T5 T6 T7 T8 T9
T1 Well-Head Y
T2 Unfired Process N (1) Y
T3 HC storage N (9) N (2) Y (3)
T4 Fired process Y (4) Y (4) N Y
T5 Machinery N (9) Y N Y Y
T6 Buildings N N (5) N (5) N (5) N Y
T7 Pipelines Y Y N (6) N N N Y
T8 Vents Y Y Y (7) N N N Y Y (7)
T9 Flares N N (8) N N N N N (7) N Y
Compatibility of the equipment groups
Explosion Measures Explosion Measures
Effect of layout on explosion severity
Description of Damage EffectsPeak side-on overpressure
(bar)
Peak side-on overpressure
(kN/m2)Typical pressure for glass breakage 0.01 1"Safe distance" (probability 0.95 no serious damage beyond this value)Missile Limit10% window glass broken
0.02 2
Limited minor structural damage 0.028 2.8
Large and small windows usually shattered; occasional damage to window frames 0.035-0.059 3.5-6.9
Minor damage to house structures 0.048 4.8
Partial collapse of walls and roofs of houses 0.138 13.8
Lower limit of serious structural damge 0.159 15.9
50% destruction of brickwork of house 0.173 17.3
Frameless, self-framing steel panel building demolished 0.207-0.276 20.7-27.6
Wooden utilities poles (telegraph, etc.) snapped 0.345 34.5
Nearly complete destruction of houses 0.345-0.483 34.5-48.3
Portable total destruction of buildings 0.69 69
Limit of crater lip 20 2000
Ref. "Classification of Hazardous Locations" Cox, Lees and Ang. Institue of Chemical Engineers, 1989 and "loss Prevention in Process Industries" Frank P Lees, Butterworth Heinemann, 1996, 2nd Edition.
Typical damage effects associated the explosion overpressure
Overpressure (psig / barg)
Equipment
a c d n
a e p d n
b f o
d k u
a m t
g i t
a l p t
h f v t
i p t
k u d
i l t
p s o
q
n l t
n l v
q t
r t
p l t
i m q
i v t
i m s v
i t
j l t
i t
i v
In this table
0.5
/ 0.0
31.
0 / 0
.07
1.5
/ 0.1
2.0
/ 0.1
42.
5 / 0
.17
3.0
/ 0.2
3.5
/ 0.2
44.
0/ 0
.27
4.5
/ 0.3
5.0
/ 0.3
45.
5 / 0
.37
6.0
/ 0.4
1
9.5
/ 0.6
510
.0 /
0.68
6.5
/ 0.4
47.
0 / 0
.48
7.5
/ 0.5
18.
0 / 0
.54
20.0
/1.3
6>2
0.0
/ >1.
36
Control house steel roof
Control house concrete roof
12.0
/ 0.
8214
.0 /
0.95
16.0
/ 1.
0918
.0 /1
.22
8.5/
0.6
09.
0 / 0
.61
Cooling tower
Tank: Cone roof
Instrument cubical
Fired heater
Reactor chemical
Filter
Regenerator
Tank: Floating roof
Reactor: Cracking
Pipe support
Utilities: Gas meters
Utilities: Electrical transformers
Electrical motors
Blower
Fractionation column
Pressure vessel: horizontal
Pump
Utilities: Gas regulator
Extraction column
Tank shpere
Pressure vessel: Vertical
Steam turbine
Heat exchanger
Blast overpressure effects on vulnerable plant parts (Stephens 1970).
Microsoft Word Document
Area F:No limitation on design
Area E:No Housing
Area D:
Area C:
Area B:
20 Area A:No occupied buildings
0 0 20 30
Size of cloud (tonnes of hydrocarbon equivalent)
Area F
Area E
Area D
Area C
Area B
Area A40 5010
Design 0.7 barg peak incident gauge pressure for 20ms. No hazardous plants (domino effect). No site roads.
Design Buildings for a peak incident gauge pressure between 0.2 to 0.7 barg. No low pressure storage tanks.
Design Buildings for a peak incident gauge pressure between 0.1 to 0.2 barg. Roof be independently supported and windows protected. No public roads.
Dist
ance
from
poi
nt o
f rel
ease
(met
ers)
300
400
500
600
100
200
Summary of the main restrictions imposed on design against gas explosions. Note: Area E limitations apply in areas E-A and so on.
(Kletz, 1988)
• equipment rupture• blast overpressure• drag forces• effects of dynamic amplification factors.• design ventilation to minimise the probability of build-up of the most likely types of gas or
vapour releases• minimise number of ignition sources and keep ignition sources near to the openings as far
as is practicable• minimise module volume• avoid long narrow modules• minimise congestion.• minimise the extent to which the obstacles block the cross-sectional area of the module• minimise the number of obstacles in the flame path between the potentially most likely
ignition location and vent• locate obstacles in the inner part of the module and away from vents• orientate obstacles so that they present their most aerodynamic profile to the main vent
flow direction• do not obstruct the openings in the module boundaries• make safety critical equipment/structures barriers as strong as reasonably practicable and
do not limit the design to a calculated explosion over-pressure• design collapse in a cascade fashion such that failure occurs first in less critical directions• consider mitigation by venting, water sprays, chemicals, and dilution.
The following effects of explosions should be considered:
Fire Measures Fire Measures
Example of Effect of Temperature on Strength of Structural Steel (From API 2218)
Heating of Unwetted Steel Plates Exposed to Gasoline Fire on One Side (From API 2218)
. .100
Open pool fires
Large or confined pool fires
Open Jet fires
Confined Jet fires
.200
.300
.400
Total incident Heat flux (kW/m2)
Fire
type
and
sev
erity
Fire intensity vs Type of fire
Fire ScenarioThe following can be used as prompts to assist the team to build a
picture of a potential incident:
• flammable gas migration to an ignition source or dispersion
• smoke/fumes migration to occupied areas
• vapour cloud explosion and overpressures generated
• boiling liquid expanded vapour explosion (BLEVE)
• jet fire length and radiant heat
• pool fire sizes and radiant heat
• boilover from a crude tank.
Fire case Relief Valve
BDV
To vent
To Safe location
Location of release
Jet fire lift upoff
Receiver
Source
9.6 kW/m2 Thermal Radiation Contour
Fire case Relief ValveBDV
To vent
To Safe location
Location of release
Jet fire lift upoff
Receiver
Source
9.6 kW/m 2 Thermal Radiation Contour
Jet fire & Escalation
- For jet fires impingement is the main concerns and not thermal radiation.
- Safety system are designed to mitigate risk of jet fire impingement.
9.6 kW/m2 Thermal Radiation Contour
Fire
XFire Fire
Fire
Need Analysis based on medium release (20 mm)
- Safety distance: distance between the source & receiver > jet fire length @ 15min
- Duration of jet fire < 15 min
- Blowdown content of source to safe location in 15 min
- Relief valve on receiver relief pressure to reach at 7 bar in 15 min
- Passive fire protection on receiver to increase the failure rate of receiver to more than duration of fire
Need Analysis based on medium release (20 mm)
HSE Plan HSE Plan
Fishbone Analysis (Six Sigma) Fishbone Analysis (Six Sigma)
Life Cycle NotionLife Cycle Notion
Project Management
Engineering Procurement Manufacturing Construction Commissioning
Plant Management
Operation Maintenance
Verification NotionVerification Notion
• Disciplinary checks
• Interdisciplinary check
• Internal independent audit
• External independent audit
PA PB PC PD PE
People Asset Environment Reputation 1 in 100,000 years
1 in 10,000 years
1 in 1,000 years
1 in 100 years
1 in 10 years
Multiple fatalities or permanent total disabilities
Extensive damage Massive effect International
impact Catastrophic S5 100000 1 10 100 1000 10000
Single fatality or permanent total disability
Major damage Major effect National impact Severe S4 10000 0,1 1 10 100 1000
Major Injury or health effects Local damage Localised effect Considerable
impact Critical S3 1000 0,01 0,1 1 10 100
Minor Injury or health effects Minor damage Minor effect Minor impact Marginal S2 100 0,001 0,01 0,1 1 10
Slight Injury or health effects Slight Damage Slight effect Slight impact Negligible S1 10 0,0001 0,001 0,01 0,1 1
Risk is unacceptable and further Risk reduction measures shall be considered Risk is ALARP. Risk is Negligible and Tolerable.
Severity Ranking
Consequence Frequency Ranking
Project Risk Ranking Matrix
PeopleSeverity Definition
5 Multiple fatalitiesMultiple fatalities from an accident or occupational illness (poisoning, cancer).
4 Single fatality or permanent total disabilitySingle fatality or permanent total disability from an accident or occupational illness (poisoning, cancer).
3 Major injury or health effects (including permanent disability)Major injury or health effect – affecting work performance in the long term, e.g. prolonged absence from work. Irreversible health damage without loss of life, e.g. noise induced loss of hearing, chronich back injuries.
2 Minor injury or health effectsaffecting work performance, e.g. restriction to activities (restricted work case – RWC) or need to take time off work to recover (lost time incident LTI). Limited, reversible health effect, e.g. skin irritation, food poisoning.
1 Slight injury or health effects Not affecting work performances.
EnvironmentSeverity Definition
5 Massive effectPersistent severe environmental damage or severe nuisance extending over a large area. In terms of commercial or recreational use or nature conservation, a major economic loss for the company. Constant high exceedance of statutory or prescribed limits.
4 Major effectSevere environmental damage. The company is required to take extensive measures to restore polluted or damaged environment to its original state. Extended exceedance of statutory or prescribed limits.
3 Localized effect Limited loss of discharges of known toxicity. Repeated exceedance of statutory or prescribed limit. Affecting neighbourhood. Spontaneous recovery of limited damage within one year.
2 Minor effectContamination. Damage sufficiently large to attack environment. Single exceedance of statutory or prescribed criterion. Single complaint. No permanent effect on the environment.
1 Slight effectLocal environmental damage. Within the fence and within the systems. Negligible financial consequences.
AssetsSeverity Definition
5 Extensive damage substantial or total loss of operation (costs in excess of $10,000,000).
4 Majorpartial operation loss (2 weeks shut down, costs up to $10,000,000)
3 Local damagepartial shutdown (can be restarted but costs up to $500,000)
2 Minor damagebrief disruption (costs less than $100,000)
1 Slight damageno disruption to operation (costs less than $10,000)
Reputation
Severity Definition
5 International impactinternational public attention. Extensive adverse attention in international media. National/international policies with potential severe impact on access to new areas, grants of licenses and/or tax legislation.
4 National impactnational public concern. Extensive adverse attention in the national media. Regional/national policies with potentially restrictive measures and/or impact on grant of licenses. Mobilisation of action groups.
3 Considerable impactregional public concern. Extensive adverse attention in local media. Slight national media and/or local/regional political attention. Adverse stance of local government and/or action groups.
2 Limited impact some local public concern. Some local media and/or political attention with potentially adverse aspects for company operations.
1 Slight impactpublic awareness may exist, but there is no public concern.
Define What should be done?
Occupational Health Assessment
(Hold)
(Hold)
HAZOP Chairman
(Hold)
(Hold)
Noise Study
RAM Study(Hold)
(Hold)
(Hold)
(Hold)
Lead Design Safety Engineer
Snamprogetti
Jermy Smith
Engineering HSE Manager
ODE
Andrew Alder
Process Safety & HSE expertODE
Fabienne Salimi
Environmental Assessment
(Hold)
(Hold)
Lead Design Safety Engineer
Snamprogetti
Fabienne Salimi
Define Who does What?
Define When and How it should be done?
Define How it is Verified?
HSE Management System HSE Management System
HSE Management SystemHSE Management System
PlanPlan, Do, , Do, CheckCheck, , ActAct
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1. Leadership and commitment
2. Policy and strategic objectivesHSE policyStrategic objectives and targets
3. Organization, Responsibilities, Resources, Standards and DocumentsOrganizational structure and responsibilitiesManagement representativeResourcesCompetenceContractorsCommunicationDocumentation and its control
4. Hazards & Effects Management Process (HEMP)Identification of hazards and effectsRisk evaluationRecording of hazard and effectsObjectives and Performance of CriteriaRisk reduction measures
5. Planning & ProceduresAsset IntegrityProcedures and work instructionsManagement of changeContingency and emergency planning
6. Implementation and MonitoringActivities and tasksMonitoringRecordsNon-compliance and corrective actionsIncident reportingIncident follow-up
7. AuditInternal auditIndependent audit
8. ReviewManagement review
Elements of an HSE management system
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