Personal & Process Safety

for Operator-1
Courtesy: HSE
Basics

Personal or Occupational Safety Hazards

Slip, Trip, Fall, Cuts, Vehicle incidents:

• Affect 1 or few people

Process Safety Hazards

Cause Major Incidents:
• May contain catastrophic consequences
• Release of potentially dangerous substances
• Fires & Explosions
• Multiple fatalities & Injuries
• Substantial environmental & economic loss
• Can affect works and communities significantly
 Process Safety

Has come to the forefront of oil and gas industry concerns as a

result of statements like this:
– BP management paid attention to, measured, and
rewarded personal safety rather than process
safety.
(Safety Board report on Texas City refinery explosion, as repeated in President’s Report on BP Deepwater Horizon Oil Spill and
Offshore Drilling, 221)

– …To understand how this operated we must first

make the distinction between occupational safety,
sometimes called personal safety, on the one hand,
and process safety on the other.
(A. Hopkins, “Management Walk-Arounds: Lessons from the Gulf of Mexico Oil Well
Blowout” [February 2011], 9)
Personal vs Process Safety
 Typical Contrasting Definitions

• …not distinguished between occupational safety—concern over

slips, strains, and other workplace accidents—and process
safety: hazard analysis, design for safety, material verification,
equipment maintenance, and process-change reporting.
(President’s Report on BP Deepwater Horizon Oil Spill and Offshore Drilling, 221)

• This corresponds to a distinction between conventional safety

risks, that result in relatively high frequency, low consequence
events (e.g., slips, trips, and falls) and major hazard risks, that
give rise to low frequency high consequence events (e.g.,
explosions).
(A. Hopkins, “Management Walk-Arounds: Lessons from the Gulf of Mexico Oil Well Blowout”
[February 2011], 9)
 Process Safety Defined, e.g.’s

The protection of people and property from episodic and

catastrophic incidents that may result from unplanned or
unexpected deviations in process conditions.
(Guidelines for Auditing Process Safety Management Systems, 2nd ed. [New York:
Center for Chemical Process Safety, 2011], xxvi)

Process Safety is a blend of engineering and management

skills focused on preventing catastrophic accidents,
particularly explosions, fires, and toxic releases, associated
with the use of chemicals and petroleum products.
(Murray Macza, “A Canadian Perspective of the History of Process Safety
Management Legislation” [Cologne, Germany, 2008], 12/2)
 Process Safety Defined, e.g.’s

Process safety is a blend of engineering and management skills

focused on preventing catastrophic accidents and near misses,
particularly structural collapse, explosions, fires and toxic
releases associated with loss of containment of energy or
dangerous substances such as chemicals and petroleum
products. These engineering and management skills exceed
those required for managing workplace safety.

(Energy Institute’s expansion of CCPS definition

[www.energyinst.org/technical/safety/process-safety])
 Defining by Contrast

• In the remaining presentation, process safety will be

illustrated through a series of simplified contrasts with
personal (aka occupational) safety

• The goal is a quick understanding of the interests of process

safety, not a nuanced definition for each

• While readily contrasted—this does not necessarily mean

they must be managed or addressed in distinct or separated
siloes!
Applicable
Personal Safety Process Safety

• …to all workplace • …primarily to process

scenarios, any
industries, e.g., – Chemical
industry
– Petrochemical –
Energy/Utility

(Any industry dealing with materials with

intrinsically hazardous properties and
subject to major accident hazard)
 Some Associated Terms
Personal Safety Process Safety

Slips, Trips, & Falls Design for Safety

Incident Reporting Management of Change Process

Unsafe Acts, Unsafe Conditions Asset Integrity

Hazard Identification Intrinsically Safe

HAZOP HAZID PHA
TBT, TRA, PPE, ALARP LOPA ALARP PSSR

Housekeeping Major Hazard / Major Accident Hazard

Human Factors
Safety Culture LLD Human Factors
Safety Culture
Pause & Re-think, Engagement eSafe Cards
LLD
SOC, eSafe Cards Incident Reporting
Focus of Concern
“Risk Matrix” Profile
Outcome
“Safety Pyramid”
Metrics

Personal Safety Process Safety

• Established metrics • Metrics subject to debate,

• SOC difficult to measure
• eSafe Cards
• DAFWC • Tier-1, 2, 3 & 4
• Kms
• Man-hrs • Both leading & lagging
• Others indicators

• Both leading & lagging

indicators
Hazard ID & Assessment
Personal Safety
• Lends itself to a wide range
of participants
• May be conducted in some
cases with minimal training
• Often managed entirely in-
house
Process Safety
• Requires technical & often
engineering expertise in
processes and materials
handled
• Frequently facilitated by
external consultants
Hazard Control
Safety Culture
Goal
Goal
Outcome
 Management System
Personal Safety
• Element A: Management Involvement and Commitment
• Element B: Hazard Identification and Assessment (includes Inspections
and Site Specific Hazard ID and Reporting)
• Element C: Hazard Control (includes Preventive Maintenance and
Hazardous Materials)
• Element D: Training
• Element E: Emergency Response
• Element F: Incident Reporting and Investigations
• Element G: Communication (includes Safety Records and Audit)
• Element H: Joint Health and Safety Committee
 Management System
Process Safety

Process safety leadership

1. Leadership commitment & responsibility
2. Identification & compliance with legislation & industry standards
3. Employee selection, placement, competency & health assurance
4. Workforce involvement
5. Communication with stakeholders
Risk identification & assessment
6. Hazard identification & risk assessment
7. Documentation, records & knowledge management
Risk management
8. Operating manuals & procedures
9. Process & operational status monitoring & handover
10. Management of operational interfaces
11. Standards & practices
12. Management of change & project management
13. Operational readiness & process start-up
14. Emergency preparedness
15. Inspection & maintenance
16. Management of safety critical devices
17. Work control, permit-to-work & test risk management
18. Contractor & supplier, selection & management
Review & improvement
19. Incident reporting & investigation
20. Audit, assurance, management review & intervention
Managed Independently?
Does an emphasis on personal safety necessarily lead to inattention to
process safety?

• Are personal safety and process safety contradictory or

complementary?

• Considerable overlap in approach and management

system elements.

– Can a company build out elements of their PSM system

from their existing Safety Management System (SMS)?
– Does the introduction of PSM elements raise the standard
for a company’s SMS?
UEP Approach – Integrated

For both Personal &

Process Safety:
• Same Risk Ranking &
Matrix & Procedure
• Same online tools for
sharing safety
observations – safe
cards & SOCs
• Same incident reporting
and investigating
protocols and tools, i.e.
KMI
• Etc.
Process Safety Indicators
Tiers explained
Tiers 1 and 2 provide lagging indicators of process safety performance.
They cover major and less severe incidents. Loss of Primary Containment (LOPC)
events are categorized as Tier 1 or 2, and indicate the failure of multiple barriers.

Tiers 3 and 4 provide leading indicators of process safety performance.

They are intended to be more specific to a company’s own management system
and often will be specific to an activity or to an individual asset, facility, or plant.

Tier 3 KPIs are used to monitor the performance of the barriers that prevent
Tier 1 and 2 LOPC events.
Events where the LOPC was below the Tier 2 thresholds, or when no LOPC
has occurred, are Tier 3 KPIs provided one or more key barriers, or supporting
systems, failed or did not function as expected. These represent challenges to
safety systems.
Tier 4 KPIs are used to monitor the implementation (operating discipline)
and effectiveness (performance) of the Management System Elements that
support the performance of key barriers.
 Interpreting Monthly HSE Report
For Personal & Process Safety Standing
Of UEP
UEP HSE KPIs – OCTOBER 2019
Man Hours Annual / Monthly Safety Inputs Annual / Monthly Safety Outputs Departments Dashboard

Incidents Statistics
This is a title slide.
PSII Driving Safety Contractors Dashboard

2019 ACTUALS (YTD Oct-19)

MAP Status

METRICS 2019 KPIs COMMENTS

UEP CONT. TOTAL

LAGGING INDICATORS

FATALITY-UEP [Number] 0 0 1 1  Total Fatality 1

[Jul(1)]

0.09 0.02
DAFWC [Frequency] <0.07 0.03  Total DAFWC: 2

The subtitle goes here. (1)

0.09
(1)

0.18
[Jan(1), (Jun(1)] [see details in slide-7]

Total RI: 13
RECORDABLE INJURIES [Frequency] <0.26 (1) (12) 0.17  [Jan(1), Feb(1), Mar(3), Apr(4),May(1), Jun(1), Jul(2)]
[see details in slide-7]

LOSS OF PRIMARY CONTAINMENT INCIDENTS–LOPC [Number]

[Hydrocarbon LOPC incidents > 10 bbls]
<4 0 0 0 
LOSS OF PRIMARY CONTAINMENT INCIDENTS–LOPC [Number]
[Hydrocarbon LOPC incidents > 1bbl]
<23 2 0 2  Jun (1), Aug(1)

SEVERE PROPERTY DAMAGE – SPD [Number]

[immoveable property, value > $100,000]
<2 0 0 0 
PROCESS SAFETY INCIDENTS [PSI] Tier-1: 0
[Any LOPC that meets IOGP defined consequences]
Monitor Tier-2: 9  Tier-2: Feb(4), Mar(1), Apr(2), Sep(2)
[see details in slide-10]

0.34 0.05 Total SVA: 3

SEVERE VEHICLE ACCIDENT RATE – SVAR [Frequency] Monitor (2) (1)
0.12  [Aug(2), Sep(1)]

LEADING INDICATORS
7355 1127
SAFETY OBSERVATIONS & CONVERSATIONS - SOC [Frequency] >1100 (77,869) (75,056) 2019  Oct-19 SOC numbers: 14,837, YTD: 152,925

13013 1914
SAFETY OBSERVATIONS - SO [Frequency] >1700 (137,775) (127,539) 3503  Oct-19 SO numbers: 27,694, YTD: 265,314

HSE TRAINING HOURS [Frequency] Monitor 2604  Oct. 19 Training hours: 23,701, YTD: 197,174

ACTION CLOSURE YTD OCTOBER-2019 [%] >97% 98%  3503 of 3571 Actions closed till Oct-19
(68 Overdue)

INCIDENTS INVESTIGATION CLOSURE [%] 100% 99%  965 of 976 Investigations completed till Oct-19
(11 Overdue)
Man-Hours worked – Last 12 months

FATALITY
DAFWC
RI
SVA
SPD
Home
Safety Inputs: Annual Frequencies

(YTD)
(YTD)

(YTD)
(YTD)

Monthly Inputs Frequencies Home

Safety Inputs: Monthly Frequencies
(Last 12 months)

YTD SOCf was 84% above the target YTD SOf was 106% above the target

In Oct-19, THrs remained 23% better then YTD average Continuous improvement since Feb-19. Currently, 68 Actions overdue (including 06 >60 days)
Annual Inputs Frequencies Home
Safety Outputs: Annual Frequencies

(YTD)

(YTD)
KPI introduced in 2006
(YTD)

(YTD)
Monthly Outputs Frequencies Home
Safety Outputs: Monthly Frequencies
(Last 12 months)

KPI introduced in 2006

Annual Outputs Frequencies Home

Department wise HSE KPIs Dashboard

Home
UEP Incidents Statistics – 2019

Home
Process Safety Incidents - 2019
(Tier-1 & Tier-2)
For detailed PSI and
Consequences of other Process
Safety Incidents (all Tiers), refer
to attached excel file

S. No. Tier Zone Location Month Brief description Justification

1 Tier 2 MKK Rajpari - 1 Feb ESV shut-in due to instrument gas line leakage Based on threshold for outdoor material release for tier-2

Tier 2 Naimat Phase- A gas leakage occurred at flange gas kit u/s
2 MKK Feb Based on threshold for outdoor material release for tier-2
5 Orifice chamber of TR-3 (5A3)
Tier 2 Badin South Mazari Feb
3 Middle plunger leak Based on threshold for outdoor material release for tier-2
North Deep - 8
Tier 2 Badin South Mazari Feb
4 JP discharge turbine meter disengaged Based on threshold for outdoor material release for tier-2
North Deep - 7
Tier 2 Naimat Phase- Mar
5 MKK Amine spilled on worker hand Release of hazardous chemical resulted in burn injury of a worker.
3
Naimat Phase Amine solution carryover from Phase-5A3 CO2 Acute release. Threshold of material(amine) released is more than
6 Tier 2 MKK Apr
V-3A vent 0.7bbl with in an hour
Tier 2 Badin South Mazari Apr Leak developed in Pump discharge PRV line at
7 Based on threshold for outdoor material release for tier-2
North Deep - 11 SMZ-11
MKK Naimat West - 3 Double Stud Adaptor Leaked The Qty of release is exceeding the threshold limit of Tier-2 limit i.e.
8 Tier 2 Sep
50 kg/hr
Badin Jagir - 3 Leak developed at flow line The Qty of release is exceeding the threshold limit of Tier-2 limit i.e.
9 Tier 2 North Sep
0.7 bbl/hr.
Home
Driving Safety
Engagement and Communication: Engagement & Communication
6 6
 Seven new GCM modules developed and added to the GCM
process to create awareness on high risk areas 5 5 5
4 4 4 4
 Pre-qualification of A,B LV Transport Contractors (Bhambro &
3 3
Nizamani) carried out
2
 Overall attendance improvement in morning and evening GCMs
for driver at field locations

 Engagement sessions on cell phone risk and prohibition

Badin MKK Badin MKK Badin MKK
conducted by RTMS team at UEP and A,B
Aug-19 Sep-19 Oct-19
 Decease in RT incident in UEP & A,B. Planned Actual

RT Incident Trend – Zones

Opportunities for Improvement:
7 7
 Random dash cam checks revealed overall compliance of UEP 6 66 6
DSS requirements 5 5 5
4 4 44 4
3 3 3 33
 Field driver rotation implemented at Badin & MKK
2 2 2 2 2
1 11 1 11 111
 Fleet replacement by non-transport contractors is at a stand still, 0
00 0 00 0
however third party certification in on-going
MKK Badin KHI UEP A, B
 RTMS Map audit actions implementation in progress Jan-19 Feb-19 Mar-19 Apr-19 May-19
Jun-19 Jul-19 Aug-19 Sep-19 Oct-19
Home
 UEP Contractor HSE KPIs Dashboard – YTD 2019
(Purple & Blue Risk Contractors)
(Overall Contractors)
In October 2019, 30 inputs (out of 99 active contractors) not received. 69 contractors submitted inputs (by 13th Nov). 9 were inactive.
For YTD - 2019, 9% (91) inputs not received and 7% (67) remained In-active.
SOC Target Frequency : 250
SO Target Frequency : 350

Frequencies Legends : Frequency above Targets Frequency under Target Zero Inputs Next Home
 UEP Contractor HSE KPIs Dashboard – YTD 2019
(Turquoise & White Risk Contractors)
SOC Target Frequency : 250
SO Target Frequency : 350

Frequencies Legends : Frequency above Targets Frequency under Target Zero Inputs
Next Home
Management Assurance Program – 2019
UEP RISK BASED HSE MANAGEMENT ASSURANCE PROGRAM - 2019
S. # DESCRIPTION AUDIT MANAGER AUDIT PARTNER Jan-19 Feb-19 Mar-19 Apr-19 May-19 Jun-19 Jul-19 Aug-19 Sep-19 Oct-19 Nov-19 Dec-19 REMARKS

REVIEWS / ASSURANCES
INTERNAL AUDIT
1 EMS 14001-2015 INTERNAL AUDIT (UEP A&B) TAJAMMAL HUSSAIN
TEAM
Moved from Sep to Oct and then
2 RIG MOVE ADEEL KAZI ASRAR AHMED Nov

3 HOSES MANAGEMENT PROCEDURE ASSURANCE SAJJAD MEMON AFTAB MEMON

4 CYLINDER MANAGEMENT PROCEDURE ASSURANCE RASHID KHAN MIAN SAJID

5 EXTERNAL EMS 14001-2015 (UEP A & B) THIRD PARTY TAJAMMAL HUSSAIN

MUHAMMAD ASIF Report
6 HITRA PROCESS ZAHEER ALAM Awaited
RASHEED
7 BOWSER SAFETY COMPLIANCE (LPG/CRUDE) GHULAM ALI YASIR MAHDI
INTERNAL AUDIT
8 IMS INTERNAL AUDIT SHAIKH AMIR
TEAM
9 PERMIT TO WORK & ENERGY ISOLATION NASIR ZAMAN M. MUBEEN

10 PERMIT TO WORK & ENERGY ISOLATION (UEP A&B) NAVEED ASLAM BADAR/NOUMAN

11 PSSR REVIEW AND IMPLEMENTATION SAQIB SIDDIQUE RIZWAN MANSHA

12 ROAD TRANSPORT MANAGEMENT SYSTEM (RTMS) TAUQEER RANA KASHIF KAMRAN

13 MANAGEMENT OF CHANGE (MOC) UZAIR ASLAM BUTT FRAZ RIZVI

14 IMS SURVEILLANCE AUDIT (EXTERNAL) THIRD PARTY FAIZAN FATMI

CONTRACTORS HSE MANAGEMENT SYSTEMS REVIEWS

1 ZPEC RIG-33 (*) AQIL RAZA DAOUD SHAIKH

2 ZPEC RIG-450 (*) SADRUDDIN H. ALI ASLAM UMRANI

3 RIG ANTON-4001 (*) SAAD MOIN USAMA SABIR

4 STEELMAN ENGINEERING SHABBIR JAN KASHIF ALI

5 ZPEC RIG-33 (*) MAUSUF AHMAD ARSHAD BASHIR

6 RIG HILONG-21 (*) WANG SHENG AFAQUE IMTIAZ

7 ASSL MUHAMMAD IKHLAS SHAZ KEERIYO

SYED JUNAID
8 ABDUL WASAY SIDDIQUI AND CO (AWS) SOHAIL A. KHAN
AHMAD
9 RIG HILONG-4002 (*) ASRAR MUHAMMAD ZIAUDDIN

10 RIG HILONG-5 (*) BRIAN LEI HASAN QAISAR Rig has been released

11 RIG ANTON 2001 (*) AMJAD SHAIKH M. ARSALAN KHAN

12 SPRINT TARIQ SHAIKH ASLAM UMRANI

Report
13 JAN M. BHATTI BHAGCHAND ZEESHAN MAZHAR Awaited

MUHAMMAD
14 SCHLUMBERGER (UEP A & B) TAIMUR AGHA
IBRAHIM
(*) Bridging document compliance audit

PLANNED DONE DEFERRED NOT DONE REPORT AWAITED Not being conducted Home
Thank You