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Pillai Sreejith
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Introduction
Offshore Safety Case Training
pillai_sreejith@hotmail.com
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11 People died
Caused by riser damage from MSV impact Texas City Refinery 2005 petroleum distillate overflowed causing explosion & flash fire 14 People died Caused by maintenance & process start-up flaws
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Major Modifications
List down the major modifications (process / marine) that occurred in your offshore installation/s in the past 1 year to tell them that the risk profile has changed:
Examples:
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Flare system modifications Addition of a hydrocarbon process equipment Change in mooring system Addition of gas compression facilities
Offshore Training pack
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steps involved:
Offshore site visit (to assess the safety critical element / barrier performance);
Risk Assessment (using realistic field inputs such as barrier performance to be used in QRA event gates in frequency analysis); and Safety Case update
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Potential Major accidents for offshore complex; Offshore Safety Case; Safety Barriers in the offshore complex / installation; and Safety training assessment.
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Key Message Once the safety systems /barriers fail, there can be major accidents!!!
Only you can operate and maintain safety systems without flaws.
pillai_sreejith@hotmail.com
Sreejith Offshore Training pack
Session Break
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pillai_sreejith@hotmail.com
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Learning objectives
To understand major accidents; To understand the difference between occupational/personal, marine and process hazards; To understand the Swiss Cheese accident causation model and Bow Tie barrier concept; To learn the importance of barriers in controlling major accidents and To appreciate the need to maintain the safety systems in order to control / mitigate major accidents.
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Major Accident
(UK HSE SC Regulations,2005 ) A Major Accident defined by UK HSE is:
A fire, explosion or the release of a dangerous substance involving death or serious personal injury to persons on the installation or engaged in an activity or in connection with it; An event involving major damage to the structure of the installation or plant affixed thereto or any loss in the stability of the installation; The collision of a helicopter with the installation; The failure of life support systems for diving operations in connection with the installation; and Any other event arising from a work activity involving death or serious personal injury to five or more persons on the installation or engaged in an activity in connection with it.
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Major Accidents
Examples Deadliest accident so far: 1988 Piper Alpha (167 fatalities); 2nd deadliest: 1980 Alexander L. Kielland Accommodation rig capsized during a storm (123 fatalities); 3rd deadliest: 1989 Seacrest drillship capsized during a typhoon (91 fatalities ); and 9th Deadliest: 2005 Mumbai High Platform fire (22 fatalities).
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Blowouts Riser & Pipeline releases Process Hydrocarbon Releases Fire & Explosion Ship Collision Dropped Objects Transportation Accidents Helicopter crash Projectile/Missile impact Structural damage Turret Failure Cargo Tank explosion
Offshore Training pack
Occupational Hazards
Personal or Occupational Health and Safety Hazards Can give rise to incidents or accidents that primarily affect one individual worker for each occurrence
Occupational Accidents
Mainly those accidents that can be controlled by the use of PPEs
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BP Texas City Refinery Fire and Explosion (15 killed, 180 injured)
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Marine Accident
Ship collision in Japanese waters causing major damage (July 27, 2007)
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Loss Iceberg
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H A Z A R D
Major accident
C O N S E Q U E N C E S
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Construction /Engineering activities Maintenance activities Offshore Training pack Operations activities
Instrumentation, i.e. TAHH / LALL / LAHH / PALL / PAHH Relief System (PSV)
Escape Routes
Emergency Lighting Emergency Power (UPS) Internal Communications & Alarms External Communications Helideck Crash Equipment Miscellaneous Safety Equipment TEMPSC & Life rafts Helicopter Facilities Direct to Sea Equipment
Inspections
Helicopter Crash
ESD system Control ESD Valves
Navigational Aids
PTW
Pedestal Cranes
CMMS Maintenance
Projectile/missile Impacts
Inert Gas System
Audits
Miscellaneous / Temporary Equipment
Transportation Accidents
Firewalls
Gaseous Systems
Ignition control
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Safety Barriers
Explanation-Example 1 Ignition Control
Hazardous Area Classification Use of Ex type equipment (do you know how they are designed? Why cant they be designed as vapour / gas tight?) Flash back arrestors, spark arrestors Static charge discharge control (bonding, when do you install bonding? Why is this done?) Lightning control (how do you control these hazards?) Inert gas system for cargo tanks Use of inert gas system to dilute hydrocarbon vapours at vents
Sreejith Offshore Training pack
Safety Barriers
Explanation-Example 2 What are the difference between Passive Fire Protection (PFP) & Active Fire Protection (AFP)? Examples of PFP?
Fire walls In tumescent coatings (ESD valves?) Heat shields on the escape routes?
Examples of AFP?
Deluge FM 200 Gaseous Fire Fighting system Fire & Gas Detection system
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A 60 Firewall
Heat Shield
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PROCESS INSTRUMENTATION
Prevention barriers
HAC Static Electric Audits
IGNITION CONTROL
Loop checks for BD Audits/Inspection CFIs on Relief Valves
Audits/Inspection
EMERGENCY SHUTDOWN
Mitigation barriers
EXPLOSION
Discuss
For major accident control, which side of the bow tie should be strong? Left (prevention) or the right side (mitigation) ? Why?
Major Accident
Discussion trigger: Can a gas explosion be effectively mitigated prevented with water deluge?
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Learning
Major accidents; Potential major accidents at your offshore installation; Difference between personal / occupational, marine and process accidents; Swiss Cheese & Bow Tie safety concepts; and Importance of safety barriers in controlling major accidents.
pillai_sreejith@hotmail.com
Sreejith Offshore Training pack
Session Break
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pillai_sreejith@hotmail.com
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Learning Objectives
To learn about the major accidents that occurred in your offshore complex to understand What went wrong?; and To think about the potential barrier failures that might exist at offshore installations which could lead to potential major accidents.
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Offshore Complex
Show the field diagram Show the platforms / FPSOs and the interconnecting pipelines Include the major additions / modifications to highlight to the participants that the installation has changed over the years
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Major Accidents
Identify major accidents, hi-potential incidents, near-misses; Discuss each of the major cases from the detail reports to explain: Causes Consequences Risk reduction recommendations Implementation status Any similar accidents occurred?
Causes
Examples
Inadequate planning / organization; Flaws in PTW procedures; Written job procedure did not anticipate contributing factors; Failure to follow known job procedure (s); Inadequate training; Supervisor failure to identify unsafe condition; and Failure to communicate.
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Learning
If no concrete action is taken to rectify the cause of
the incident permanently, it might lead to an accident next time round History has proven this;
Accidents could happen even with safety barriers in place; Personnel play an extremely important role in promoting safety competency, experience and knowledge is important; and
We need to ensure that the safety barriers are maintained so as to control / mitigate accidents.
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Session Break
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In this presentation, the typical potential major accidents for FPSO / platform are included. This will require customisation in line with the field QRA results.
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pillai_sreejith@hotmail.com
Offshore Training pack
Learning Objectives
To learn about the potential major accidents that can occur in offshore field and to understand the consequences; To be aware of the major risk contributors at offshore installations; and To be aware of the risk levels for various personnel at your offshore field.
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9. Structural damage
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Risk Terminology
Individual Risk (IR) Individual Risk Per Annum is the frequency with which an individual may be expected to sustain fatal harm due to exposure to specific hazards in a year
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ALARP Triangle
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Manning distribution Transportation details Heat & Material Balance diagram P&IDs PFDs General Arrangement / Layouts Design basis and safety philosophies
Offshore Training pack
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Offshore Installation Areas Show the areas considered in the QRA Explain the manning distribution of various personnel categories in the areas Tell them the risks calculated is rather realistic since we have considered more facts
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Flash Fire
Sreejith the causes and consequences Offshoreof Training Explain eachpack type of fires including their impairment potential
Impairment
Discuss impingement and impairment from pool and jet fires Pool fire impingement on steel structures:
10 minutes
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Frequency Analysis and Event Tree Analysis: Frequency of each accidental event (top event) and branch probabilities are assigned to event tree and outcome event frequency are estimated.
Consequence Modelling: Using the software. The physical effects and damages for each outcome event are estimated
Impact Assessment: Analyse the fire and explosion impact to structures and equipment.
Risk Assessment Fatality Estimation: Determine the risk to personnel from each outcome event. Risk Summation and Risk Ranking: Sum the risks to individual from each outcome events for hydrocarbon and non-hydrocarbon hazards and identify the dominant risk contributors. Risk Assessment: Compare the risk levels against Individual Risk Acceptability Criteria to determine whether additional measures are necessary to reduce risks to ALARP.
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Risk reducing measures: Apply enhanced or additional control measures and mitigation measures.
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Fire Contours
Show the jet, pool fire contours superimposed on the offshore installation layout drawing to show them the potential effects.
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Transportation Accidents
Helicopter, boat, personnel transfers
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ANOA FIELD
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Consequences: Asset damage (hull, equipment, platform, etc.) Multiple fatalities / injuries
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Protection from side & vertical impacts? Personnel falling from height due to giddiness, loss of grip, high wind, loss of balance, etc.
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Is there an option?
Consequences:
Fire Major asset / helicopter damage Multiple fatalities / injuries
There are hardly any known occurrences of Helicopter crashing into FPSO or platform
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Consequences:
Asset damage (hull, equipment, etc.) Multiple fatalities / injuries
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Overall Risk for Offshore Complex Explain the Individual Risk (IR) for the various personnel categories;
Explain the PLL (Potential Loss Of Life) values for the complex and various personnel categories;
Discuss if the IR value is within the ALARP tolerable region;
Explain what is traffic light system and how is it used to determine Realistic Risk levels?
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How will the TL System used to calculate impairment / event Offshore Training pack frequencies in QRA?
Partially degraded
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Learning
Individual Risk for all offshore personnel are within the acceptable limits; Understanding potential major accidents for offshore installations (causes and consequences); Understanding the major risk contributors at offshore field; and Understanding the personnel risk levels for various categories.
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Session Break
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pilliai_sreejith@hotmail.com
Sreejith Offshore Training pack
Learning objectives
To understand the objective of Safety Cases; To understand The UK HSE Offshore Installations (Safety Case) Regulations 2005; To understand the typical SC update triggers; and To know the Typical Safety Case contents.
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Safety Case-Definition
A documented body of evidence that provides a convincing and valid argument that a system is adequately safe for a given application in a given environment
Safety Case exists for Nuclear, Offshore, Aviation, and Rail industries
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UK Offshore Operators, says Cullen, must adopt this new philosophy on safety, producing a Safety Case'. This includes continuous hazard assessment over the plant's lifetime, fault tree analysis, which looks at all the ways an error could develop, and takes account of ways that 'human factors' contribute to disasters
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Forthwith: Immediate, at once Lord Cullen recommended that the 4 (FEA, ESSA, EERA,SIGA) be carried out by the offshore operators immediately before the 1992 safety case regulation was released. Sreejith Offshore Training pack
Safety Case
First SC Regulations came into force in 1992; Cullen Forthwith studies:
A Fire Risk Analysis; An assessment of the risk of ingress of smoke or gas into the accommodation; A review of the ability of emergency systems to withstand severe accident conditions; and An evacuation, escape and rescue analysis.
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-The requirement for duty holders to send an early design notification, instead of a design safety case, to HSE when establishing a new production installation; -Duty holders are required to carry out a thorough and fundamental review of their safety cases at least every five years, or as directed by HSE; -The present requirement to re-submit safety cases every three years has been removed (inspectors will be checking to see that safety cases are being kept up to date through inspection); -New duties require licensees to ensure anyone they appoint as an operator is capable of fulfilling their legal responsibilities for safety; -Combined operations safety cases have been replaced by notifications, which do not need HSE acceptance; and -The Offshore Installations (Safety Representatives and Safety Committees) Regulations have been amended to extend consultation with safety representatives to reviewing and revising a safety case, as well as preparing one.
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Learning
Origin and objectives of Safety Case; Piper Alpha Accident & Safety Case; The UK HSE Offshore Installations (Safety Case) Regulations 2005; Typical SC contents; and Typical SC update triggers.
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Session Break
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pillai_sreejith@hotmail.com
Sreejith Offshore Training pack
Learning objectives
To understand the critical role of safety barriers / safety systems in controlling major accidents using Bow-Tie diagram; To understand safety barriers on offshore installations; To appreciate the need to maintain the barriers through maintenance system, inspections, etc.; and To identify and monitor performance of safety barriers through lead and lag indicators.
Sreejith Offshore Training pack
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MAE
Preventative
Instrumentation, i.e. TAHH / LALL / LAHH / PALL / PAHH Relief System (PSV)
Escape Routes
Emergency Lighting Emergency Power (UPS) Internal Communications & Alarms External Communications Helideck Crash Equipment Miscellaneous Safety Equipment TEMPSC & Life rafts Helicopter Facilities Direct to Sea Equipment
Inspections
Helicopter Crash
ESD system Control ESD Valves
Navigational Aids
PTW
Pedestal Cranes
CMMS
Projectile/missile Impacts
Inert Gas System
Audits
Turret failures
Cargo tank explosions
Firewalls
Gaseous Systems
Ignition control
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Accident Trajectory
Lagging indicator
Lagging indicator
Leading indicator
Lagging indicator
Permit-to-work
Leading indicator
Staff Competence
System defects
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PROCESS INSTRUMENTATION
HAC Static Electric Audits
IGNITION CONTROL
Loop checks for BD Audits/Inspection CFIs on Relief Valves
Audits/Inspection
EMERGENCY SHUTDOWN
Fire Drills Audits CFT on Fire Pumps & Valves Testing of foam concentrate MOC
EXPLOSION
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Partially degraded
MAE
Preventative
Instrumentation, i.e. TAHH / LALL / LAHH / PALL / PAHH Relief System (PSV)
Escape Routes
Emergency Lighting Emergency Power (UPS) Internal Communications & Alarms External Communications Helideck Crash Equipment Miscellaneous Safety Equipment TEMPSC & Life rafts Helicopter Facilities Direct to Sea Equipment
Inspections
Helicopter Crash
ESD system Control ESD Valves
Navigational Aids
PTW
Pedestal Cranes
CMMS
Projectile/missile Impacts
Inert Gas System
Audits
Turret failures
Cargo tank explosions
Firewalls
Gaseous Systems
Ignition control
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Maintenance Management
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Learning
Concept of Safety barriers in major accident control; and Role of offshore personnel in ensuring integrity of safety barriers by monitoring performance indicators; and Performance of safety systems to control major hazards cannot be monitored using LTIs which calls for a shift in focus.
Sreejith Offshore Training pack
Key Message
pillai_sreejith@hotmail.com
Sreejith Offshore Training pack