Integrity Management Initiative

at Woodside Brownfield Projects

Lincoln Fernandes
Graduate Risk Engineer, Transfield-Worley WEL (ISC)

Transfield Worley Services 2008

TW - Woodside Brownfield Projects

Engineering and execution for Woodsides NWS assets:
Goodwyn A

Transfield Worley Services 2008

Karratha Gas Plant

North Rankin A

Why the concern?

Spotlight on the Oil & Gas Industry

- BP Texas City Refinery

- Alon USA Big Springs Refinery
NOPSA: Increasing Nationwide trend

- 45% rise in HCT releases since Q1 2005

Our analysis of containment loss incidents
in the HC industry

Transfield Worley Services 2008

Timeline to Inception
Analysis of uncontrolled releases
Review of incident investigation
Review of immediate fixes
Global organisational improvement
Transfield Worley Services 2008

Gas Release - SBF Failure

Drain line modification during compressor
plant upgrade

- Compressor recycle line upgraded from 8

to 10

- New pipe support required for the

upgraded line

- Drain line off recycle line also upgraded,

from 1 to 2

- Existing 1 drain valve retained

reducer to connect new drain line to old valve

Transfield Worley Services 2008

What happened?
Weld at reducer cracked approx 180 degrees
around the weld, resulting in a gas release
Failure noticed by personnel and the
compressor was shutdown
Failure due to fatigue caused by
acoustically induced vibration
< 2 hours to full failure:

- full bore 25mm release

- 7MPa gas source
Transfield Worley Services 2008

What happened?

Transfield Worley Services 2008

Immediate Investigation
Numerous co-incident contributing causes:

Fatigue analysis not performed

Additional pipe support omitted

Vibration measurement incorrect
Drawing procedure error

Transfield Worley Services 2008

Initial Outcomes of Incident

Procedures modified
Roles and responsibilities modified
Organisational changes
Lessons Learned:

- Value of every detail

- Need for vigilance
- Schedule never above integrity
Transfield Worley Services 2008

Critical Review of Work System

Process safety workshops:

- Management
- Team Leaders
- Client
Finding:
Global step-change is required
=
Integrity Management Initiative
Transfield Worley Services 2008

Vision Management Initiative

Integrity
An Asset has Integrity when, under specified operating
conditions,
there
no intolerable
risk of
failure endangering
Zero harm to
the is
integrity
of personnel,
environment
or asset
the safety of personnel, environment or asset value

Transfield Worley Services 2008

Plan of Action
Global deficiencies to be addressed
Workshops aimed at organisational
improvement of:

- Systems and Processes

- Personnel and Organisational
Competencies

- Tools to measure performance

- The Culture of awareness of
process safety

Transfield Worley Services 2008

Improving Systems and Processes

Actions:

Review, rationalise & improve

accessibility

- Internal / Workshares
- 3rd Party Contractors

Increased external peer review

Cross learning of roles

Improve induction process

Transfield Worley Services 2008

Competencies Workshop
Actions:

Improved Competency Framework

Leadership Management training for

Team Leaders

Increase site visits

Increased HSE in Design training

Asset specific training

Transfield Worley Services 2008

Workshop on Culture of Awareness

Actions:
Continuous improvement:

More communication!

- Enhance inductions
- Communications Sessions
- Process Safety Moments
- Empowerment through

Transfield Worley Services 2008

Workshop on Culture of Awareness

Excellent opportunity for the Initiative
Behavioural HSE Management System

Promotes awareness of HSE

systems

Promotes positive view towards

safety

Promotes accountability

Transfield Worley Services 2008

Measuring Integrity Management

Asset Integrity Measurements:

Lagging

- Failures revealed by incidents

Leading

- SCE testing on schedule

- Failures discovered during testing

Engineering Measurements

In progress

Transfield Worley Services 2008

Communicate the Safety Case

The Safety Case is legally binding!

Describes accidents and

consequences

Details mitigation, control and

responsibilities

And

Transfield Worley Services 2008

Communicate the Safety Case

Most Importantly:

Demonstrates systematic and

continual management to achieve
ALARP

Sound familiar ?

Transfield Worley Services 2008

What we are trying to prevent

Major Accident Events

Fatality

Environmental Damage

Community Impact

Asset Loss

But what is a Major Accident Event ?

Transfield Worley Services 2008

What a Major Accident might look like

The power of
Photoshop!

Transfield Worley Services 2008

What does it add up to?

NOPSA: Root Cause of Topside Releases:

43%
Human Performance
Deficiencies

57%
www.nopsa.gov.au
01/2005 - 10/2007
Transfield Worley Services 2008

Equipment Difficulties

Integrity Management Initiative

Going Forward:

Continue global organisational improvement

- Rationalise Systems and Procedures

- Retain and develop personnel
- Indicators of performance
- Make it a visible issue!

Zero integrity incidents!

Transfield Worley Services 2008

Thanks for Your Time!

If you have any further questions or suggestions,
please do not hesitate to contact me!
Lincoln Fernandes
Graduate Risk Engineer
Transfield-Worley - WEL (Integrated Services Contract)
 +61 8 9338 7818 (Tel)
 Woodside Plaza, Mailstop 10-17
fernandesl@transfield-worley.com.au
Transfield Worley Services 2008