Understanding Process
Safety in Operations
9 November 2023
Table of Content
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Introduction
Process Safety in
Operation
Hazard Identification &
Risk Assessment
Management of Change
2
Introduction
What is Process Safety ?
Process Safety is a disciplined framework for managing the integrity of hazardous operating
systems and processes by applying good design principles, engineering and operating
practices. It deals with the prevention and control of incidents that have the potential to release
hazardous materials or energy. Such incidents can cause toxic effects, fire or explosion and
could that can have an impact on people, plant and the environment.
High Consequences. Low Likelihood
3
Introduction
Process Safety Incident
Flixbborough. 1/06/1974
Fire & Explosion
28 Fatalities 53 injuries
Piper offshore, UK. 6/07/1988
Fire & Explosion
167 Fatalities
Buncefield, UK. 11/12/2005
Fire & Explosion
43 injuries
Bhopal, India. 3/12/1984
Toxic gas release.
2,153 Fatalities 200,000 injuries
Texas City, US. 23/03/2005
Fire & Explosion
15 Fatalities 180 injuries
Gulf of Mexico, US. 20/04/2010
Fire & Explosion
11 Fatalities 17 injuries
4
Introduction
2,153 Fatalities ; $???
11 Fatalities; > $60B
2010, Deep Water Horizon, USA
Drilling rig explosion
43 Injured; $894M
1984, Bhopal, India
Toxic gas release
2005, Buncefield, UK
Oil Storage Explosion
22 Fatalities ; $300M
2005, Mumbai High, India
Vessel collided with platform
15 Fatalities; 180
injured; > $2B
2005, Texas Refinery, USA
Hydrocarbon vapor cloud
explosion
1988, Piper Alpha, UK
Platform explosion
167 Fatalities;
$3.4B
1974, Flixborough, UK
Fire & Explosion
28 Fatalities ; $359M
5
2,153 Fatalities ; $???
11 Fatalities; > $60B
43 Injured; $894M
2010, Deep Water Horizon, USA
Drilling rig explosion
1984, Bhopal, India
Toxic gas release
2005, Buncefield, UK
Oil Storage Explosion
15 Fatalities; 180
injured; > $2B
2,153 Fatalities ;
$300M
2005, Mumbai High, India
Vessel collided with platform
2005, Texas Refinery, USA
Hydrocarbon vapor cloud
explosion
1988, Piper Alpha, UK
Platform explosion
167 Fatalities;
$3.4B
Regardless the likelihood, Oil & Gas industries
are exposed to potential MAJOR ACCIDENT with
consequences considerably
CATASTROPHIC/DISASTROUS TO HUMAN,
ASSET, ENVIRONMENT, FINANCIAL,
REPUTATION AND GLOBAL BUSINESS
1974, Flixborough, UK
Fire & Explosion
28 Fatalities ; $359M
PT KILANG PERTAMINA INTERNASIONAL
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Process Safety in Operation
Why are lessons not learned?
Preventing process accidents requires vigilance
Passing of time without a major accident hazard is not an
indication that all is safe and may lead to complacency
People may lose appreciation of safety systems which can
then lead to:
• Deterioration of controls and safety systems
• Lessons learnt and training may be forgotten
• Deviations from safe operating procedures may become common
• Increasing reliance on how things were done in the past
7
Hazard Identification & Risk Assessment
What you don’t have can’t leak … (Trevor Kletz)
8
Process Safety in Operation
The Regulator’s Expectation
Three Key questions that must be answered
Do we understand what can
go wrong ?
Do we know what systems
are in place to prevent things
going wrong ?
Do we know that these
systems are working
effectifevly ?
9
Process Safety in Operation
Every steps of the cycle should have clear outcome
Operate
Concept
Build
Commission
Start Up
Maintain
Plant Life Cycle
Shutdown
Decommission
Modify
We are focusing on Operation phase which
includes Operation, Maintenance, and
modification. What do we have to manage
in this phase.
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Process Safety in Operation
Asset Integrity Management
Asset integrity management involves the ongoing effort to maintain the reliability of assets, ensuring their
safe, efficient, and effective operation. This includes safeguarding people, assets, the environment, and the
community from potential accidents or hazards throughout the facility's lifespan.
Managing asset integrity during the operational phase of facility’s life cycle consists of several activities :
• Initially starting up the facility in a manner such that the integrity of the facility assets is not compromised
• Operating the facility within its intended design parameters
• Recognizing deviations from the intended integrity and properly responding to these deviations
• preventive/predictive maintenance tasks on schedule and tracking/ trending result
• Monitoring the condition of assets
• Executing safe transient operations such as shutdowns and restarts
• Managing changes to the facility
• Detecting primary containment and safeguarding deficiencies and failures
• Correcting deficiencies and failures as they arise
11
Process Safety in Operation
Management of Change
42% of incidents that
occurred between 1966
and 2015 identified a
Management of Change
(MOC) as one of their root
causes.
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Process Safety in Operation
What is MOC
A process to review and authorise changes in facility design, operations, organisation, or activities
prior to implementation to make sure that no unforeseen new hazards are introduced and that the
risk of existing hazards to people, assets, and environment are not unknowingly increased.
Key Principles of MOC :
• Maintain dependable practice
• Identify potential change situations
• Evaluate possible impacts
• Decide whether to allow change
• Complete follow-up activities
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