Project Life Cycle Safety Suite 3_PLCS.pdf · Project Life Cycle Safety Suite Athens, Safety Gala,...

Project Life Cycle Safety Suite

Eleftheropoulos Dimitris, Safety Consultant, MFG


Athens, Safety Gala, 13th June 2019



Objectives

• Overall approach

• Define the role of SAFETY in the overall business

• Run through all phases

• Discuss optimisation of business

• Discuss about tools that can support optimisation

• Software examples

• Wrap up

Safety is not first. Safety is an integrated element of the business.

Our main scope and objective is our Project /plant, our business which has to be executed EFFECTIVELY.



THE RESULT

“ Every system is producing the results it is designed for”

Donald Mark Berwick

…the premise being that both the intended and unintended

consequences are designed into our systems.



REVIEW PROJECT LIFE CYCLEConcept Preliminary

designBasic

design Detail design

FEED Construction Testing & commissioning

Hand over

O&M Decommissioning

THE CONCEPT

250 t

800 t/h

`

1.000 t/h

250 t/h

22.500 t

22.500 t

400 t/h

375 t/h

7.500 t 7.500 t.

250 t/h

480t/h

(bauxite)

270t 250 t

187,2t/h 45 t/h 1,2 t/h 3,6 t/h

25t

Vertical Raw mill

280 t/h HGG: 50,16GJ/h

150 t/h60t/h

Coal Pet

Coke

Bag filter

High Temp 120 t/h

100m3

213 t/h

Reclaimer 60 t/h

230 t/h BF dust Raw coal

100t 150 m3

5 stages 15 t/h

ILC Preheater

9,6t/h x 1,05

5,2t/h x 1,05

25t/h

150/250t/h Storage

Bauxite ILS Limestone

150t/h 3000 t 3.000t 1.000 t

600t/h

480t/h

30m3

(clinker) 600t/h 3x300t/h 480 t/h

3-300t/h

250t/h

300t/h

to trucks

25m3

600 t 600 t

200t/h

HGG: 30,16GJ/h

3.000bags/h (50kg)

4.000bags/h (25kg)

6.000 t 6.000 t 6.000 t

100 t

fly ash fly ash

Grate Cooler

Clinker storage

Vertical Coal mill

Bag

Filter

Rotary Kiln 3.300 t/d

Bag filter

300t 100 t

corrective material

truck hopper

IBAU (CC)

7.000 t

Limestone Flysch Iron corrective silo

500 t 270 t

Raw

limestone

(quarry)Raw clayhopper

(quarry)

100 t

Coal storage

IV 32,5 N

6.000 t

Raw coal

150 m3

Pozollan

5.000 t 5.000 t

Pulverized coal

100 t

Pulverized coal

100 t

Packing Plant Palletizing Plant

100 pallets/h

I 42,5 N

1.000 t

I 42,5 R II 32,5 N

100t

Pallet storage

5.000 pallets (two rows)

Lignite

3x7.000t

Gypsum

Clinker Limestone Gypsum Pozzolan

40.000 t

fly ash

Off standard

clinker silo

Grinding aid

20m3

THE DESIGN MANAGEMENT OF INHERENT OPERATIONAL & EMERGING RISKS

It should be borne in mind that reducing the risks from an existing plant ALARP may still result in a

level of residual risk which is higher than that which would be achieved by reducing the risks

ALARP in a similar, new plant.

Factors which could lead to this difference include (holistic approach) :

• practicability of retrofitting a measure on an existing plant,

• the extra cost of retrofitting measures compared to embedded them in a new plant,

• the risks involved in installation of the retrofitted measure; and

• the projected lifetime of the existing plant .



THE STORY (THE SEQUENSE)

Once upon a time …



PRELIMENARY PHASE (STAGE 0)

People decided to build a new plant. They defined then the minimumsafety standards to follow, determining the risk inherent to the operationphase, or the selection of the equipment and technology determined itselfthe risk to be inherited.

Specifications for main equipment, design factors, technology, etc are theresult of a thorough Risk Assessment already performed by the industry,since main equipment, design philosophy etc have been assessed bymanufacturers, practice and law.



RISK ASSESSMENT - STAGE 0

Stage 0 Design basis, core specifications, selection of land/location



DESIGN PHASE (STAGE 1)Developing (Detailing) the design, specific safety studies are carried out to assess

and/or quantify associated risks and confirm design and design specs as well as

operational needs.

• Hazard and Operability Studies (Hazop)

• Hazard Identification (Hazid)

• ATEX (explosive atmospheres)

• Safety Integrity level (SIL)

• Quantitative Risk Assessment (QRAs)

• Health and Safety File (HSF)

• Stress analysis

• Fire study

• Earthquake study

• Signing and labeling study

P8-161-001-NT-EL MERK_PID Safety Review Report - EXTRACT.doc

QRA.ppt




Stage 0Design basis, core specifications, selection of land

Stage 1 Safety Studies, Quantitative and Qualitative Risk assessment



ROUTINE OPERATION & MAINTENANCE (STAGE 2)

Considering:

• Safety Studies findings and recommendations;

• Operational philosophy;

• Management systems in place;

• Staffing;

• Works given out / outsourced (contractors);

• and the alike…

Then a Plant’s Qualitative Risk Assessment is prepared and it is

incorporated into the OPS manuals and the management procedures.






Stage 2

Qualitative RA for the routine status of the Plant, incorporated into the Ops manuals and Management Systems procedures



ROUTINE AND NON ROUTINE OPERATION &

MAINTENANCE (STAGE 3)

Based on the standard stuff, confirm / revise Plant’s RA on spot for the particular:

• Systems included

• Personnel

• Environment

• Equipment

• Layout – alignment

• Procedure to be followed

• Weather, timeschedule, … ; and

prepare for that work a specific RA based on the method statement and vice versa






Stage 2

Qualitative RA for the routine status of the Plant, incorporated into the Ops manuals and Management Systems procedures

Stage 3

Qualitative Work Specific RA, based and interlinked with the particular work and its specific method statement, together with the standard system in place (e.g. PtW, LoTo, etc)

The Way WE Approach Safety

Take care of Safety totally in all aspects

OR

Approach Safety Holistically

The word holistic comes from the Greek word “Όλος”(holos), meaning “entire” or “all”.



How WE implement Safety



Safety Management System (SMS) is a comprehensive management system designed to manage safety elements in the workplace.

How WE implement Safety



1. Safety Audit

2. SIR Software

3. RAM Software

Something is MISSING…



Key Components – Key Issues Continuous Monitoring

Personnel - Safe Pass

Equipment - Safe Pass

MSDS – Material Safe Pass

Method Statements

Training

Corrective Actions – NCR Log

Permitting System

Incidents Log

Labour Inspectorate

Drills

Lifting Plans

Statistics

Metrics

KPIs



Why PLCS?



A project life cycle is the sequence of phases that a

project goes through from its initiation to its closure.

The number and sequence of the cycle are determined by

the management and various other factors like needs of

the organization involved in the project, the nature of the

project, and its area of application. The phases have a

definite start, end, and control point and are constrained

by time. The project lifecycle can be defined and

modified as per the needs and aspects of the

organization. Even though every project has a definite

start and end, the particular objectives, deliverables,

and activities vary widely.

An organized way to

ensure that adequate

planning and procedures

exists that make certain

that the Safety System

shall meet the

requirements

The Idea



Key Features



• Each Component – MODULE- can be designed from scratch…

Can add / create a new module to satisfy the requirement,

• Can use all or selected modules,

• Built in libraries, fully customizable,

• Documentation upload,

• Can run as main platform hosting various projects,

• Customizable Alert system.

PLCS Initial Input - Modules



• Site Equipment

• Accessories

• Trainings

• MSDS

• Permit to Work register

• Fire Extinguishers

• Incidents

• Meetings

• Drills

• PPE Inspection

• Subcontractors Designated Safety Engineers Visits

• Construction Documentation (Lifting Plans &

Method Statements)

• Labour Inspectorate activity

• HS Team & Third Party Action Tracking Register

• Subcontractor’s Documentation Status

• Consequences Management System (penalty reg)

• Safe Pass issuance

• Personnel Specialty / Subctr’s manpower

• Scaffolds

PLCS Benefits



• Active Libraries;

• Statistical analysis;

• Action Tracking;

• Inspections aiding data;

• Work Site organisation tool;

• HS Coordination & Management Data;

• HSP implementation documentation.

Conclusions



Software aided PSM, characteristics and objectives

1. Practicability

2. Simplicity – friendly to user

3. Built for purpose Focus (Design for purpose)

4. No overlaps

5. Completeness

6. Effectiveness

7. Productivity

8. Support decision making

9. Culture change

10. Support continuous improvement



THANK YOU FOR YOUR

ATTENTION

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Project Life Cycle Safety Suite 3_PLCS.pdf · Project Life Cycle Safety Suite Athens, Safety Gala,...

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