TECHNICAL MEETMEETTAMILNADU

ENGINEERS FORUM,
KUWAIT
Safety Engineering for Oil &
Gas Industry Operational
Plants

J RAMESH BABU

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AGENDA
About Cholamandalam MS Risk Services Ltd.
Safety Engineering studies for Operational plants
Case studies

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CMSRS SERVICES POTFOLIO

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Services Offered by CMSRS Contd.,

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Our Global Foot Prints

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Global Risk Technology Center [GRTC]

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Accolades

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WINNER OF RISK MANAGER OF THE YEAR AWARD

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NAPESCO our partner in Kuwait

a leading national oil field services provider

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OTHER ACCOLADES
APPROVED HEALTH & SAFETY CONSULTANTS FOR KUWAIT
OIL COMPANY UNDER 31 S CATEGORY ( ONLY ASIAN
COMPANY)
APPROVED FOR CONSULTANCY STUDIES AT KUWAIT
NATIONAL PETROLEUM COMPANY ON PROJECT TO
PROJECT BASIS
APPROVED FOR CONSULTANCY STUDIES AT AL KHAFJI
JOINT OPERATIONS OF SAUDI ARAMCO OIL COMPANY AT
SAUDI ARABIA ON PROJECT TO PROJECT BASIS

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Risk Based Inspection

Identification of risks of each equipment on the risk matrix
Selection of type of maintenance and frequency of
inspection

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Risk & Reliability Management - Concept

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RRM Process

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Standards adopted
API publication 581- Base Resource Document: Risk
Based Inspection
API 580 Recommended Practice for Risk Based
Inspection

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Health Safety Environment Critical

Equipment System (HSECES) for
Refinery and Off shore Facilities

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HSECES
HSE Critical Equipment and Systems
(HSECES)
Parts of an installation and such of its structures, plant
equipment and systems (including computer programmes)
or any part thereof, the failure of which could cause or
contribute substantially to; or a purpose of which is to
prevent or limit the effect of a major accident or any
accident with severe or catastrophic consequences

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CRITICAL EQUIPMENT

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Fire Safety Audit / Fire Risk Assessment

Identification of fire risks and assessment of fire

risks based on Risk Assessment technique
suggested by Fire Precautions at Workplace Act,
UK
Recommendation of fire prevention measures
Fire / smoke spread hazards and suggesting
control measures
Review of Passive Fire Protection System (PFPS)
Identification of heat / smoke detection
requirements
Review of Active Fire Protection System (AFPS) as
per TAC & NFPA standards

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Fire & Explosion Hazard Management system

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Process of FEHM

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CHAZOP STUDY FOR ELECTRICAL/ ELECTRONIC/ PL SYSTEMS

OBJECTIVE
To analyze the types of failure modes of new system (independently and in
conjunction with other new/existing equipment) and to ensure that sufficient
redundancy/fall back arrangement is provided and the introduction of the
new system does not result in unsafe plant operation
SCOPE
Hazards and Operability Study, HAZOPS, is a Systematic Structured
Discovery technique to identify hazardous consequences due to deviations
from designers intentions. The scope of the study covers all the
Instruments and Control systems like DCS, ESD, Field Instruments, Local
Control Panel, UPS, paging system, etc. including new design and
revamping of existing facilities.
The study will also undertake a Safety Integrity Level (SIL) assessment for
all safety related electrical/ electronic/ programmable electronic systems

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PROCESS SAFETY AUDITS/ SAFETY AUDITS

Comprehensive Safety Audit as per IS 14489 /OHSAS 18001
Review of 31 SMS elements
Combination of Engineering and System based solutions
Comprehensive Approach similar to that of a health check up
Should address ground level realities
Should have performance based approach
Can be objective (Adoption of Scoring Pattern)

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Process Safety Management

14 Elements of PSM

Employee Participation
Process Safety Information
Process Hazard Analysis
Operating Procedures
Training
Contractors
Pre-startup Safety Review

Mechanical Integrity
Hot-work Permits
Management of Change
Incident Investigations
Emergency Planning & Response
Compliance Safety Audits
Trade Secrets

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Safety Perception Survey

SPS part of culture change management, a step
further to OHSAS 18001, to understand employees
safety perception better
Specific SPS questionnaire for each employee category
Developed a software to analyze survey data collected
Carried out SPS for a 9 MMTPA refinery
100
93.75
90.62

90

86.59

84.55
80

79.83

83.85

79.21
72.5

70
62.5
60

50

40

30

20

10

EMPLOYEE
EMPOWERMENT

MANAGEMENT CLIMATE

MANAGEMENT
COMMITMENT

QUALITY OF
SUPERVISON

RECOGNITION OF
PERFORMANCE

Category 1

93.75

90.62

72.5

62.5

Category 2

79.83

79.21

84.55

83.85

86.59

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Disaster Management Planning

Disaster Management Plan can be evolved

as per standards US EPA, NFPA 1600,
local statutes and corporate standards
Should be scenario based
Specific and detail procedures should be
developed
Periodically rehearsed
Periodically updated
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ELECTRICAL SAFETY AUDIT

Comprehensive Electrical Safety Reviews
(Earthing, ESD, HAC, Lightning, accidents, protection,WPs, sample tests)
Lightning Protection Reviews

Electrical Hotspot Detection Surveys

Thermographic Surveys

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LIGHTNING PROTECTION REVIEW

Review of LP based on IS 2309 /NFPA 780/API RP 2003/OISD 180

Use of LP Risk Assessment software, based on BS 6651

Risk Based design preferred

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Thermography Surveys

Part of E-RBM Programme

In the De-Tariff scenario, may be offered free by general insurance
companies
Identification of potential survey points / equipment and
interpretation - very crucial
NFPA 70 E recommends Thermographic surveys

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Accident Investigation

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The Aim of the Investigation

THE KEY RESULT SHOULD BE TO PREVENT A RECURRENCE

OF THE SAME ACCIDENT

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INVESTIGATION STRATEGY
GATHER INFORMATION & ESTABLISH FACTS
ISOLATE ESSENTIAL CONTRIBUTORY FACTORS
DETERMINE CORRECTIVE ACTIONS
IMPLEMENT CORRECTIVE ACTIONS

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Accident Investigation Techniques

Fault Tree Analysis

Fishbone / Ischikawa Diagram

Why Why Analysis

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Fault Tree Analysis

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Fish bone / Ischikawa

Diagram

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S tr a in s
B u rn s
C u ts
U

ng

ua

rd

ed

Br
ok
en

ac

rs
H o
hi

to
ol
s
C h e
m ic
al s
p ill
D e
fe c
tiv e
P P
E
U n tra
in e d w
o rk e r

p e c t
F a ils to in s

F a ils to e n fo r c e

L a c k o f tim e
o rk
u c h w
T o m

N o o r ie n ta tio n p r o c e s s
In a d e q u a te tr a in in g p la n
N o a c c o u n ta b ilit y p o lic y

F a ils
to tra
in

Lack of vision No mission statement

N o d is c ip lin e p r o c e d u r e s

la y

a rd
h az
a
a te
C re
z a rd
a h a
e
r
ry
Ig n o
n ju
i
t
or
ep
o r
t
ils
Fa

ne

In a d e q u a te tr a in in g

ep

N o r e c o g n itio n
In a d e q u a te la b e lin g

O u td a te d h a z c o m

p ro g ra m

N o r e c o g n itio n p la n

N o in s p e c tio n p o lic y

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Stage 5
Certainty

Moving towards Excellence

High

Stage 4
Wisdom

Low

TQM Maturity

Stage 3
Enlightenment
Stage 2
Awakening
Stage 1
(Cosmetic)
Crisis
Management

Sustainabilit
y
Behavior based
Interventions

Self Assessments
Improvement program
Measurement Program
Supporting MIS
Satisfaction Surveys,
ISO 9000. ISO 14001, OHSAS 18001

re s
u
at tion
m
Im n i z a
ga
r
O

Business Processes Mapped

SHEQ Strategic Planning
Ad-Hoc Risk Assessments
Ad-hoc Training
Ad-Hoc Management Reviews
Ad-Hoc Annual Audits

Crisis Management
10 12 Years
Time
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