Peter Ament

Process Safety at Tata Steel IJmuiden

Together we make the difference

Introduction to Tata Steel

Together we make the difference

Process Safety at Tata Steel IJmuiden Tata Steel Slide 3

Introduction to the Tata Group

One of the world’s fastest-growing and most reputable corporations

Tata Group

 Founded in 1868
 Operations in more than 100
countries and 600,000 employees
 Total revenues of more than $109
billion (68% from outside India)
 Ranked world’s 11th most reputable
and 17th most innovative company
 Promoter company Tata Sons 66%
owned by philanthropic trusts
 £100 million invested in community
projects every year
Process Safety at Tata Steel IJmuiden Tata Steel Slide 4

Tata Steel Group

One of the world’s most geographically-diversified steel producers

Tata Steel Group

 11th largest global steel producer

 Annual crude steel capacity of more
than 28 million tonnes
 Around 75,000 employees
 Manufacturing operations in 26
countries across five continents
 Present in both mature and
developing markets
 Turnover in 2015-16:
approximately $ 17.7 billion (€15.5
billion)
 Fortune 500 company
Process Safety at Tata Steel IJmuiden Tata Steel Slide 5

Tata Steel Group

A global network serving demanding markets worldwide

Western
Europe

Scandinavia

Western CIS
Europe
CEE
North America
Turkey China
Japan
Western Hong Kong
Africa India
SE Asia

Key
Steel making operations
Distribution and Latin
downstream assets America South
Sales offices Africa
New Zealand
Process Safety at Tata Steel IJmuiden Tata Steel Slide 6

Tata Steel: Europe’s second largest steel producer

Products and services that create advantage

Our advanced capabilities

 Comprehensive range of steel

products and related services
supplying into demanding markets
 Manufacturing sites in the UK and
the Netherlands, Germany, France,
Canada the US and Belgium.
Presence in more than 35 countries
 12.9 mtpa crude steel capacity
 2015-16: Turnover €8.66 billion
 23,000 employees
Process Safety at Tata Steel IJmuiden Tata Steel Slide 7

Tata Steels European assets

Tata Steel in Europe

3 steelmaking sites
25 downstream manufacturing locations
including electrical, plated and
pre finished steels, tubes
30 distribution and service centres
Rotherham 16 countries with sales office presence
IJmuiden 6 businesses manufacturing products
Port Talbot for building systems

Steel making sites

Process Safety at Tata Steel IJmuiden Tata Steel Slide 8

Our key markets

Serving the most demanding markets worldwide

Aerospace Consumer products Automotive Construction

Lifting & excavating Defence & security Energy & power Packaging
Process Safety at Tata Steel IJmuiden Tata Steel Slide 9

Tata Steel in IJmuiden

Process Safety at Tata Steel IJmuiden Tata Steel Slide 10

Tata Steel in IJmuiden: high-quality processes

TS IJmuiden produces high-quality hot-rolled, cold-rolled and coated steel

Raw materials - Pig iron - Steelmaking - Casting - Rolling - Coating

Process Safety in the Steel Industry

Together we make the difference

Process Safety at Tata Steel IJmuiden Tata Steel Slide 12
Process Safety at Tata Steel IJmuiden Tata Steel Slide 13
Process Safety at Tata Steel IJmuiden Tata Steel Slide 14
Process Safety at Tata Steel IJmuiden Tata Steel Slide 15
Process Safety at Tata Steel IJmuiden Tata Steel Slide 16
Process Safety at Tata Steel IJmuiden Tata Steel Slide 17
Process Safety at Tata Steel IJmuiden
Blast furnace no. 5 Port Talbot
Incident
Explosion
 Explosion in blast furnace no.5 in Port Talbot
18 November 2001.
 An explosion in the blast furnace resulted in
lifting the shaft of the furnace with 75 cm (±
5000 tons of weight. About 200 tons of hot
matter was released.
 3 fatalities, 12 serious injuries.
Direct cause
 Water into the blast furnace. The exact
mechanism is still not fully understood.
Follow up
 The accident was the start of structured
program to improve process safety within
Tatasteel Europe.
Tata Steel Slide 18
Lesson learned
Management
 Role and function if the safety department is
essential (involvement in process risk
evaluation).
 In the steel industry efforts on preventive
process safety studies were insufficient.
Operational
 Cooling of the blast furnace was not reliable
enough.
 Fast detection of cooling water leakage and
procedures for corrective measures and
training on these procedures was insufficient.
Engineering
 Engineering did not pay sufficient attention to
process safety risks (reliability engineering).
 Safety critical equipment was not identified
and treated as such (e.g. cooling water
pumps).
Process Safety at Tata Steel IJmuiden Tata Steel Slide 19
Process Safety in Study Design and Build

Together we make the difference

 Process Safety at Tata Steel IJmuiden Tata Steel Slide 21

Six-stage Hazard Study Process

(plus two)

Inherent SHE considerations

R&D phase
HHF/HHI assessment: High-level classification
Early study that considers: Feeds into company HHF register; audit programme;
•The nature of the process hazard high-level KPIs; PHR programme management
‘PHR0’
•The worst that can happen
•HHF effects
HS0 Scale-up / concept phase

Guideword-driven study: PHR1 Process Hazard Review -

•Identifies process hazard event scenarios recommended methodology for cyclic
HS1 •Layers of protection required in detailed study of existing plant:
design Reconfirms PHR0 and requires more in-
Flowsheet design phase depth information gathering to understand
in principle the worst PS incident.
HS2 Deviation analysis (HazOp ): PHR1 is similar to HS1 and also defines
•From design expectations the PHR2 plan for the facility.
•What if? PHR2 is an ‘installation-level’ study similar
•Operability considered to HS2 using guideword-driven team study
HS3 •Also SIL, FMECA etc. studies at this time
PHR2 to understand the process hazard event
Detailed design phase scenarios and layers of protection.
Cyclic PHR is not as onerous as the ‘first-
Field check: time round’
•Did we build what the detailed design
HS4 called for?
End of construction – before commissioning

Field check:
HS5 •Is it safe / compliant with OHS rules? Use of detailed study tools
End of construction – before commissioning Level 3 study
e.g. HazOp, FMECA,
FTA, CTA, Bowtie
Early operational review:
•Incidents
HS6
•Issues
•Learning
After 6 months operation

Plant improvements, SIL

determination, operating
HS7 - Cyclic study Ongoing cyclic study procedures, maintenance
ALARP demonstration (ongoing)
(ongoing) See ‘existing plant’ routines, training, audits etc.

Pictorial representation of recommended process hazards analyses through plant life cycle
Process Safety at Tata Steel IJmuiden Tata Steel Slide 22

Tata Steel IJmuiden risk grid

Consequence severity consequence word model

Category Description Safety and health Environment Financial A B1 B2 C1 C2 D1 D2 E1 E2 F
MATTE; Very large excess of
allow able emissions; Very
Off-site fatality; multiple on
5 catastrophic site fatalities (≥5)
serious contamination of > € 100 mln 5A 5B1 5B2 5C1 5C2 5D1 5D2 5E1 5E2 5F
ground or w ater course;
Long term loss of aquatic life
€ 10 - 100
4b On-site fatalities (2 to 4) 4bA 4bB1 4bB2 4bC1 4bC2 4bD1 4bD2 4bE1 4bE2 4bF
mln
Single on-site fatality; one or Excess of allow able
major
few on-site major injuries; emissions and serious € 10 - 100
4a 4aA 4aB1 4aB2 4aC1 4aC2 4aD1 4aD2 4aE1 4aE2 4aF
high level of carcinogen damage to the environment mln
exposure MATTE at EC threshold
One or few off-site MTCs; Repeated limited excess of
one or few on-site major allow able emissions disturing
3 severe injuries (LTIs, disablements); visual evidence; fish killed, € 0,5 - 10 mln 3A 3B1 3B2 3C1 3C2 3D1 3D2 3E1 3E2 3F
distressing exposure, vegetation killed; possible
irreversible effects MATTE
Off-site distress; one or few
on-site MTCs (serious
Excess of allow able
injuries); release 2-5 times
emissions; notifiable release, € 100.000 -
2 moderate OEL; sustained or repeated
possible w arning from 500.000
2A 2B1 2B2 2C1 2C2 2D1 2D2 2E1 2E2 2F
nuisance, noise, smell, dust,
Competent Authority
flaring or venting; LoC w ith
safety consequences
Off-site nuisance; one or few
Small amount relased to
on-site FACs; release above
w ater course; reelease may € 10,000 -
1 minor OEL, short duration nuisance,
be notifiable to Competent 100,000
1A 1B1 1B2 1C1 1C2 1D1 1D2 1E1 1E2 1F
noise, smell, dust, flaring,
Authority
venting, LoC
Incident leading to no injuries
Incident w ith no significant or
or exposure on site; minor
0 not significant persistent environmental < € 10.000 0A 0B1 0B2 0C1 0C2 0D1 0D2 0E1 0E2 0F
damage only; no off-site
effects
effects
Category A B1 B2 C1 C2 D1 D2 E1 E2 F
Frequency range (/yr) 10-9 to 10-8 10-8 to 10-7 10-7 to 10-6 10-6 to 10-5 10-5 to 10-4 10-4 to 10-3 10-3 to 10-2 10-2 to 10-1 10-1 to 1 1 to 10
barely
Description extremely unlikely very unlikely unlikely possible probable regular
conceivable
Likelyhood w ord m odel Never heard of Theoretically Foreseeable Foreseeable Foreseeable Incidents Incidents Could occur Has occured Has occured in
possible but event but event but event but know n in know n in during during lifetime recent lifetime
never heard of extremely rare chance of chance of industry; industry. May remaining of facility of installation
Likelyhood in our industry in industry occuring is occuring is Unlikely event require tw o lifetime of and likely to
very low - low - requires not expected layers of installation. recur in the
requires the the failure of during lifetime protection to Root causes next year
failure of many several layers of installation; fail have been
layers of of protection Probably seen during
protection requires tw o lifetime of the
layers of installation
protection to
fail
Process Safety at Tata Steel IJmuiden Tata Steel Slide 23

Process Safety approach for projects in high hazard installations

consequence
4&5
scenario’s

HAZID HAZOP LOPA - SIL SRS SAP

HS2 study in the form HS3 study: HS3 study: Safety Requirement Incorporation of the
of Hazard Hazard and Layer Of Protection Specifications (SRS) testing, inspection
Identification Operability Study Analysis (LOPA) describing the safety and maintenance
(HAZOP) resulting in loops and how the requirements in the
High level assess- including risk requirements for requirements from site maintenance
ment of process assessment Safety Integrity standard IEC 61511 system (SAP).
hazards in an early using the TSE risk Systems (SIS) and are met.
project stage. grid, identification of Safety Integrity
safety critical equip- Levels (SIL) for This includes
ment. identified safety testing, inspection
loops. and maintenance
Detailed study on the requirements.
basis of P&IDs.

First assessment of
SIL requirements.
Process Safety in Use Phase
by Integrity Regimes

Together we make the difference

Process Safety at Tata Steel IJmuiden Tata Steel Slide 25

Tata Steel Europe Process Safety Critical Equipment approach

Process Safety at Tata Steel IJmuiden Tata Steel Slide 26

Process Safety and Technical Integrity

Design Technical
Integrity Integrity

Hardware barrières are

Our risks are As Low present and in a good
As Reasonably condition
Possible (ALARP)

Operational
Operators are
Integrity competent and stick to
the procedures
Process Safety at Tata Steel IJmuiden
Parallel approach
PHR 3
• Similar to study design
build process
• For highest risk
installations
• No brainer: should do
Procedural barrier
Tata Steel Slide 27
PHR 2
Bow Tie Integrity Management
• Barrier management • Based on standardized
approach technical approach
• Study for scenario’s with • Also other equipment
risk category 4 and 5 than process safety
critical
• Only active en passive
barriers
Active barrier Passive barrier
Process Safety at Tata Steel IJmuiden Tata Steel Slide 28

Approach to implementation of Integrity Management

Group level Performance

Laws and
PHR 0 standards
regulations

Site level Passive barrier management

PHR 1
Inspection &
Safety Regimes
Maintenance
Report

Active barrier management

PHR 2 PHR 3 Safety Inspection & SAP PM,
loops Tests Procedures,
Instructions

Organizational management
Procedures Instructions

Audits
Process Safety at Tata Steel IJmuiden
Integrity Management
Integrity Management
according Lloyd’s:
‘The physical asset complies with the
relevant laws and regulations
and to the requirements set by the organization
in terms of risk, performance and costs’
“Make sure in a cost efficient way
that we don’t get surprises that
could have been foreseen”
Tata Steel Slide 29
 Availability
 Product quality & production
continuity
 “License to Operate”
 Reduction of (unplanned) stops
 Continuously being to demonstrate
the integrity of the installation
 Support maintenance choices
 Used for CAPEX / OPEX
investment proposals
 Basis for repairs and modifications
 Safety
 Assurance of process safety
 Input for Process Hazard Reviews
 Environment
 Reduces Loss of Containments
Process Safety at Tata Steel IJmuiden Tata Steel Slide 30

Strategy Integrity Management

 To ensure the technical integrity of installations by:

1. classify the installation in inspection regimes

2. monitor and perform the integrity inspections centrally

 Prerequisite is the centralization of process, knowledge and

assessment ability

Regime = same type of installation,

same inspection and test approach
Process Safety at Tata Steel IJmuiden Tata Steel Slide 31

Inspections and Integrity Management

Replace
Determination when a part
Maintenance needs to be replaced
Inspection
Determined by
degradation mechanism

Adjust
that occurs Determine when process
settings need to be adjusted

Inspections

Integrity
Determine the actual
condition of the installation
Integrity Inspection
Determined by Integrity
degradation mechanism Management

End-of-life
that might occur
Determine the remaining
life time of the installation
Process Safety at Tata Steel IJmuiden Tata Steel Slide 32

Current Integrity Regimes

Inspection Management
Local, FMECA, Optimiser+
All installations

Integrity Management
Law- and Regulations
Critical constructions

Cranes and crane tracks

Process Safety
Chimneys
Law- and Regulations
Pressure Vessels
Blast Furnaces

Works Arising Gas Systems

Atmospheric Storage Tanks
Process Piping
Proces Vessels
Safety Systems
Process Safety at Tata Steel IJmuiden Tata Steel Slide 33

Relation between Integrity Management and Process Safety

Barrier Management
Passive Active Procedural

WAGS

PPIR

PVIR
DHR
DTD

TIR

SIS

…
…

…
PS CE Integrity Regimes

Law- and Process Safety

regulations
Installations

HSE CE

Company
policy
MAN CE
Process Safety at Tata Steel IJmuiden Tata Steel Slide 34

Organization of Integrity Regimes

 Level 3
 Set up and secure inspection
Integrity Regime regime
 Determine inspection plan
 Assessment ability
 Monitoring and auditing
Level 3
Asses
 Level 2
 Inspect
Level 2  Report
Inspect
 Advise
Level 1  Level 1
Measure
 Measure (e.g. NDT)
Process Safety at Tata Steel IJmuiden Tata Steel Slide 35

Manning the Integrity Regimes

Regime 1 Regime 2 Regime ..

Level 3

Level 2

Level 1

Own staff
Hired staff / Outsourcing
Together we make the difference
Process Safety at Tata Steel IJmuiden Tata Steel Slide 37