Process Safety Management Standard

STANDARD
PROCESS SAFETY MANAGEMENT
Process Safety Management Standard

DIR Number: 10000011181 Printed: 8/02/2018 10:10 AM
DIR Version: 01 DIR Status: RL
Location: All Gen Ops Page 1 of 23
Printed copies of this document are uncontrolled unless contained in a site manual.
STANDARD
1. Purpose
The purpose of this Standard is to set out the management expectations considered essential in
the management of process hazards with the potential for major accident events with a focus on
managing and reducing process safety risks so far as is reasonably practicable. This Process
Safety Management Standard therefore provides a framework and common expectations for
managing the risks inherent in our business and is intended to be followed by all operating units.
By setting out clear aims and objectives, systems to manage major process safety and technical
risks can be established and implemented in a way which allows their effectiveness to be
monitored and measured. Clear visibility on the effectiveness of the processes allows for any
deterioration within critical systems to be identified and corrected before they weaken or defeat
barriers to major accident events.
2. Application
This standard applies to the design, commissioning, operation and decommissioning of all
Contact generating assets, gas storage facilities, natural gas pipelines and LPG facilities
(including reticulation systems).
3. Responsibilities
The Chief Generation and Development Officer is responsible for ensuring process safety risks
are identified and managed in a way that reduces these risks so far as is reasonably
practicable. Process safety risk management approaches will be fully aligned with Contact’s
HSE Management System and will support the company’s number one priority of achieving a
Generative Safety Culture that delivers Zero Harm.
4. Process Safety Management Framework

The Process Safety Management Standard is underpinned by a common Process Safety
Management Framework that will be used to manage hazards and risks through eight risk
control areas. The control areas are as follows:
 Technical Risk Management

STANDARD
 Safety Critical Systems

 Alarm and Instrument Management
 Maintenance Management
 Operations Management
 Staff Competence
 Emergency Preparedness
 Operations & Compliance Audit
Within each risk control area, there are a number of risk control systems which can be reviewed
to continuously improve processes and safety performance. The Framework including the Risk
control areas and systems are illustrated on the following page. The Aims and Expectations
associated with each of the framework risk control areas are set out in detail in subsequent
sections.

STANDARD
Figure 1: Process Safety Management Framework

STANDARD
Control Area 1 - Technical Risk Management

Aims
Ensure technical risk is managed through the application of robust change processes, a common risk
based framework and best practice engineering standards.
Ensure that a comprehensive hazard identification and risk assessment process is implemented to
systematically identify, assess, understand and appropriately reduce the Major Accident Event (MAE)
risk, arising from Contact’s operations, so far as is reasonably practicable.
Ensure that critical risk controls and their performance requirements are identified, understood,
documented and managed. Ensure facilities, and modifications to facilities, are designed to achieve
safe operation with risk reduced so far as is reasonably practicable.
Expectations
Management of Change
 All changes are implemented in line with the Management of Change process
 The Management of Change process: Clearly defines what constitutes a change
(including organisational change and temporary modifications) including changes to:
 Assets, equipment or plant, including changes to equipment design limits (e.g.
derating of equipment design integrity following inspection)

 Operations (including Safe Operating Envelopes) or operating procedures
 Products, materials or substances
 Organisation or personnel (safety-critical roles)
 Software or control systems
 Designs or specifications
 Standards or practices, and
 Inspection, maintenance or testing programs
 Includes a risk and ALARP assessment of the proposed change
 Ensures all proposed modifications are subject to the degree of scrutiny and oversight
appropriate to the assessed level of risk
 Provides a formalised and standardised approach for documenting the proposed
change
 Defines authority levels for approving the proposed changes
 Tracks the communication and close out of the change
 Identifies any training requirements
 Identifies controlled documents that need to be updated

STANDARD

Ensures that the original scope and duration of all changes (including temporary
modifications) are not exceeded without review or formal approval
Plant Status Review/Technical Risk
 Plant Status Reviews are undertaken on a regular basis with critical risks identified, addressed
and documented
 Competent persons use a standard approach to Process Hazard Analysis (PHA) which shall:
 Identify and document hazards that have the potential for major accident events (MAEs)
 Identify and document threats to the containment of hazards, consequences of loss of
containment of hazards and the critical barriers/controls required to prevent and mitigate
the loss of hazard containment and MAEs
 Evaluate the MAE risk and seeks to reduce the risk so far as it is reasonably practicable
 Require formal demonstration that MAE risk has been reduce so far as is reasonably
practicable
 Be reviewed at an appropriate frequency or when significant changes to plant, process
and the organisation occur or when there is a deficiency identified in the effectiveness of
the barriers/controls
 Capital investments are based on an integrated assessment of asset condition, asset criticality
and commercial impact
Strategic Spares
 Strategic spares reviews are undertaken on a regular basis and for plant modifications to
identify the necessary spares, test equipment and protection devices and to ensure that these
are available when needed
Engineering Standards
 Approved engineering standards and procedures, that meet or exceed applicable regulatory
requirements, are fully utilised in the design, procurement and construction of all new or
modified assets
 A quality assurance process is implemented that ensures assets and materials specified,
received and used, meet design specifications and engineering standards
Technical Knowledge Management
 A Technical Knowledge Management System is established to control:
 Maintenance records
 Drawings
 Asset Information/Specification
 Plant manuals
 Modifications
 Failures/Investigations
 Operating/maintenance procedures/life plans
 Knowledge of the history of plant is retained and updated

STANDARD
Design Review
 Any performance or integrity related issues identified during the course of design are
documented, assessed, verified and where appropriate, resolved
 HAZOP/SIL assessments are carried out in line with IEC 61508 and IEC 61511 Process
Industry standards
 Human factors principles are fully assessed and incorporated in the design of new or modified
assets
 Hazard analyses and safety assessments are reviewed when there is a significant change to
plant, process and/or safeguarding and at specified intervals, as deemed appropriate
 The appropriate Technical Authority reviews and accepts all external design and engineering
activities
 Complete and update hazard analyses and safety assessments during the various design
stages, including documentation and tracking of hazard, operability and integrity related issues
identified during the course of design
 Procure and construct plant, assets and facilities in accordance with the design basis
 Implement a quality assurance process to control activities undertaken as part of design,
procurement, fabrication, installation and commissioning/ completions to ensure that the design
criteria are met at each project phase
 Manage project design changes through a Management of Change process
 Develop, during the design stage, the documentation required for operations and, prior to start-
up, hand over the documentation to Operations, e.g. ‘As-built’ design records, safe operating
envelopes, operating parameters, alarm parameters and lifecycle asset integrity strategies and
supporting implementation plans
Asset Investment
 The Principles contained in ISO55000 are used as a framework for asset management across
all assets
Civil Asset Inspections
 Civil Structures are identified and inspection programmes based on risk are in place and
monitored
 Inspection of dams shall be in accordance with the principles contained in the NZ Society of
Large Dams Guidelines.
Pressure System Safety
 Compliance with pressure equipment safety Regulations and approved codes of practice and
standards is highly visible within the organisation
 Where appropriate, inspection programmes based on risk are in place and monitored

STANDARD
Control Area 2 – Safety Critical Systems

Aims
Ensure critical systems are actively inspected, tested and maintained to ensure operation and
availability to the required standard.
Expectations
 Safety critical equipment is identified and configured within the Computerised Maintenance
Management System (CMMS)
 Appropriate inspection, testing and maintenance procedures that consider applicable
performance standards are recorded in the CMMS and are implemented
 Risk of operation with impaired Safety Critical Equipment is managed
 The temporary disarming or deactivation of critical systems and subsequent reactivation are
performed in a timely manner by means of a formal procedure
 Identify, document and manage Safety critical equipment standards and performance on a
continuous basis
 Controls are established for deviating from maintenance and inspection programs (eg
inspection and testing intervals)
Critical Systems
 There is a routine programme of surveillance, monitoring. maintenance, inspection and testing
of plant, providing recognition and correction of defects and fault conditions in critical systems
Emergency Supplies
of emergency supplies, providing recognition and correction of defects and fault conditions
 The temporary disabling of emergency supplies and subsequent reactivation are risk assessed
and performed in a timely manner by means of a formal procedure
Fire Systems
 Compliance with fire safety systems Regulations is highly visible within the organisation
of fire systems, providing recognition and correction of defects and fault conditions
 The temporary disabling or deactivation of fire detection and protection systems/devices and
subsequent reactivation are risk assessed and performed in a timely manner by means of a
formal procedure
HV Electrical Systems
of HV electrical systems, providing recognition and correction of defects and fault conditions

STANDARD
Main Protection Systems
 Protection systems/devices are routinely and actively inspected, maintained and tested to
ensure full operation
 The temporary disarming or deactivation of protection systems/devices and subsequent
reactivation are risk assessed and performed in a timely manner by means of a formal
procedure
Environmental Systems
of environmental systems, providing recognition and correction of defects and fault conditions

STANDARD
Control Area 3 - Alarm and Instrument Management
Aims
Ensure alarms are prioritised consistently and actively managed to resolution; Ensure there are no long
term standing/shelved alarms; Ensure control loops are optimised and in control.
Expectations
Process Control
 Human-Computer Interface (HCI) systems are designed and implemented in line with EEMUA
201
 Control loops are in control and optimised
Critical Instrumentation
 Safety Instrumented Systems (SIS) are designed, engineered, verified, installed,
commissioned, validated, operated, maintained, and continuously improved in line with the IEC
61508 / 61511 Process Industry standards
Protective Systems/Devices
 Protection systems/devices are actively inspected, maintained and tested to ensure full
operation
 The temporary disarming or deactivation of protection systems/devices and subsequent
reactivation are performed in a timely manner by means of a formal procedure
Alarm Systems
 Alarms are prioritised effectively and actively managed to resolution in line with EEMUA 191
and IAS 18.1/2
 Operators are able to identify abnormal events and take clearly defined action on receipt of
alarms
 Critical process alarm set points are defined, current and commensurate with the defined safe
operating envelope. Procedures for making changes to set points are defined and implemented.
Operational Technology Security
 An Operational Technology Security Policy Is in place and compliance is monitored

STANDARD
Control Area 4 - Maintenance Management
Aims
Ensure that there is a common maintenance strategy across all asset types by classification; Ensure
that work is captured, prioritised, planned, scheduled and executed using a proactive approach
common to all assets.
Expectations
Work Prioritisation, Planning and Scheduling
 Work is captured, prioritised, planned and scheduled to assure the inspection, monitoring,
testing and maintenance of equipment
 A Conditioned Based Maintenance Policy and Strategy is in place and implemented.
 A procedure is in place to prioritise risks to personnel, assets, the public and the environment to
enable appropriate management of the risk
Work Identification and Routine Plant Inspections
 Maintenance and inspection procedures are developed and include, where appropriate:
 Specialised procedures for higher risk activities
 Operating envelope considerations
 Regulatory and environmental considerations
 Human factors considerations
 Failure trends and information on persistent integrity and reliability issues are periodically
reviewed and assessed; subsequent recommendations are proactively addresses to improve
reliability and operational efficiency
 Maintenance and inspection procedures are independently verified for technical accuracy and
are reviewed at periodic intervals and when changes are made. Operating procedures clearly
define or reference the process design and performance standards, specified limits and
operating envelopes for process and equipment operation
Work Execution
 Work permits incorporate all necessary risk assessments, method statements, checks and
authorisations to execute work safely
 Work history is maintained
Personal Risk Assessment
 Personal risk assessments are performed by qualified personnel and where appropriate,
suitable external expertise is sought
 A procedure is in place to periodically review the quality of personal risk assessments
Control Area 5 - Operations Management

Aims
STANDARD
Ensure that there are common operational standards established and implemented across all assets;
Ensure plant is operated within its design parameters and according to agreed procedures; Ensure
plant is put back into operation safely following an outage or commissioning.
Expectations
Start Up/Shutdown Procedures
 A pre-start up review is performed and documented to ensure that:
 Materials and equipment are in accordance with specifications
 Emergency, operations and maintenance procedures are in place and adequate
 All risk management recommendations have been addressed and required actions
taken
 Personnel have received suitable training
 Regulatory and permit requirements have been met
 There are formal plant start-up and shutdown procedures in place are each site to ensure safe
shutdown and return of the plant
 Arrangements are in place to confirm fitness for return to service before restarting an asset that
has been subjected to conditions beyond the original design parameters, after an overhaul or
after an event that has potentially threatened the integrity of the asset
Routine Plant Checks/Testing
 There is a routine programme of surveillance, monitoring and testing of plant, providing
recognition of defects and fault conditions in plant and systems
Shift Log/Handover
 A system is in place to ensure plant status and safety risks are formally passed over from shift
to shift
 Shift handover information is formally captured in electronic logs
 Operating events and status are formally captured in electronic logs
Safety Rules and Personal Risk Assessments

 Implement a Safety Rules system which includes procedures for locking, tagging and isolation
of equipment (including risk base selection of isolation schemes) and a system to register
isolations
 All personnel comply with the company safety rules
 Risk assessments are conducted for appropriate activities in order to identify and address
potential hazards to personnel, assets, the public and the environment
Operating Limits/Envelopes
 Plant is operated to defined parameters of engineering design and within envelopes of
performance capability and environmental compliance

STANDARD
Operational Risk Assessment
 Operational risk assessments are performed by qualified personnel and where appropriate,
suitable external expertise is sought
 A procedure is in place to periodically review the quality of operational risk assessments
 Operational Incidents/Near Misses are always reported and learning points are built into
improved operation

STANDARD
Control Area 6 - Staff Competence
Aims
Ensure that staff and contractors have the required knowledge, skills and resources to operate and
maintain the plant effectively and safely. Ensure a Process Safety culture is embedded at all levels
within the organisation.
Expectations
Competency Assurance
 A competence management system and assurance programme is in place to ensure that:
 Staff have the required knowledge, skills and competence to enable effective and safe
operation and maintenance of the plant
 Staff have the required knowledge and skills to react under emergency conditions
 Staff competence is regularly reviewed and assessed to identify any skills and
knowledge gaps
 Staff competence levels are maintained to assure the on-going integrity of operations
Leadership
 All leaders are trained and competent in process safety principles
 All leaders have clear process safety objectives and performance is evaluated against these
objectives
 All leaders visibly demonstrate commitment to process safety activities across relevant areas of
responsibility
 All leaders communicate expectations for and monitor progress with respect to the
implementation of the Process Safety Management Standard
Training Needs Analysis
 A process is in place for assessing the qualifications and skills needed by employees to meet
specified job requirements
 Training programmes are in place to address any skills and knowledge gaps
Communications
 A communication strategy is implemented for distribution of process safety information,
including:
 Corporate requirements
 Site based hazards
 Procedures and practices
 Lessons learned from incident investigations
 Process safety performance and improvement goals
Staff Knowledge Management
 A process is in place to ensure that necessary levels of individual and collective experience and
knowledge are maintained and are carefully considered when personnel changes are made

STANDARD
Contractor Competency
 Third party services are evaluated and selected using criteria that include an assessment of
capabilities to perform work in a safe and environmentally sound manner
 Third parties are responsible for providing personnel appropriately screened, trained, qualified
and able to perform specified duties competently
 Third party performance is monitored and assessed, feedback is provided, and deficiencies are
corrected

STANDARD
Control Area 7 - Emergency Preparedness
Aims
Ensure robust emergency response and crisis management plans are established and regularly tested.
Ensure Site Induction processes include key process safety elements.
Expectations
Emergency Planning, Arrangements and Equipment
 Emergency response plans are in place at each site and are tested on a regular basis to
simulate and prepare personnel for major incidents
 Equipment, facilities and trained personnel needed for emergency response are defined and
readily available
 Emergency response plans are clearly communicated to all employees, contractors, partners
and appropriate government agencies
 Site inductions include information on what personnel should do in the event of an emergency
 Emergency response plans will comply with industry recommended practices, corporate and
regulatory requirements
 Learnings from emergency response simulations and tests are captured and addressed
 Community expectations and concerns about our operations are sought, recognised and
addressed in a timely manner
Crisis Management
 Crisis management plans are in place and are tested on a regular basis to ensure appropriate
response action is taken. Crisis management plans will ensure:
 Site based emergency response plans are appropriately integrated
 Organisational responsibilities and authorities are clearly defined
 Internal and external communications procedures are clearly defined
 Procedures for accessing personnel and equipment are clearly defined
 Procedures for accessing essential process safety information is clearly defined
 Procedures for interfacing with other companies and external emergency response
services are clearly defined
 Crisis management plans are clearly communicated to all employees, contractors, partners and
appropriate government agencies
 Crisis management plans will comply with industry recommended practices, corporate and
regulatory requirements
 Learnings from crisis management tests are captured and addressed
Environmental Containment Systems
 Risks and potential impacts to the environment are periodically assessed and reviewed within
our operations

STANDARD
Control Area 8 - Operations & Compliance Audit
Aims
Ensure the principles contained in ISO55000 are used as aframework for asset management across all
assets. Ensure that there is an integrated audit programme in place that independently checks
processes and procedures against best practice standards. Ensure audit observations are proactively
addressed through rolling continual improvements.
Expectations
External Audit
 A process is implemented to:
 Ensure on-going compliance with all regulatory and corporate requirements
 Report and manage any non-compliance to, planned deviations from, or potential
violations of regulatory and corporate requirements
 Identify, track and comment on proposed legislation, regulations and emerging policy
issues
 Critical processes are independently reviewed on a regular basis
Integrated Internal Audit
 Applicable laws, regulations, permits and other government requirements are anticipated and
met; the resulting requirements are documented and communicated to those affected
 Process safety audits are carried out on a routine basis
Incident Reporting, Investigation and Action Tracking
 All incidents, including near misses, are reported, documented and maintained in the incident
management system
 The incident management process ensures that:
 Incident investigations carried out reflect the actual and potential severity of the incident
 Incidents are periodically reviewed to identify trends and potential system weaknesses.
Recommendations are made to address any issues identified or potential improvements
to standards, processes, procedures and practices
 Follow-up, preventative and corrective actions are prioritised and tracked to conclusion
in a timely manner
 Industry wide safety alerts are captured and communicated to all relevant personnel
 Lessons learned from incident investigations and near misses are communicated to the
organisation
 Audit recommendations and observations are prioritised and tracked to conclusion in a timely
manner
Controlled Documents (Policies, Procedures and Standards)
 Policies, procedures and standards are in line with industry best
practice/guidelines/regulations/standards
 All controlled document are stored in the document management system
STANDARD
 The document management process ensures that:
 Drawings, pertinent records and documentation necessary to effectively manage the
design, operation, inspection of sites are identified, accessible, accurate and
appropriately safeguarded
 Information on the potential hazards of equipment and materials involved in operations
is kept current and accessible
 Information on applicable laws and regulations, licenses, permits, codes, standards and
practices is documented and kept current
 Controlled documents are clearly identified, managed and are periodically reviewed/updated

STANDARD
Definitions
Term Definition
Barrier A functional grouping of safeguards, such as primary containment, process
equipment, engineered systems, operational procedures, management systems, or
worker capabilities designed to prevent LOPC and other types of asset integrity or
process safety events, and mitigate any potential consequences of such events. A
set of barriers is also often referred to as a risk control system
Hazard A hazard is anything (condition or situation) that has the potential to do harm and/or
cause damage. Hazards may be present in processing equipment (e.g. flammable or
toxic chemicals in a pipe or a vessel, stored electrical or mechanical energy) or in the
occupational environment (e.g. fuel in a road vehicle, the potential and kinetic energy
involved in helicopter travel or bullying in the workplace)
Key Performance In the context of the Process Safety Management Standard, information or data that
Indicator (KPI) provides evidence of the company managing its asset integrity and process safety
performance. A functional grouping of safeguards, such as primary containment,
process equipment, engineered systems, operational procedures, management
systems, or worker capabilities designed to prevent LOPC and other types of asset
integrity or process safety events, and mitigate any potential consequences of such
events. A set of barriers is also often referred to as a risk control system
Loss of Primary An unplanned or uncontrolled release of energy or of any material from primary
Containment containment, including non-toxic and non-flammable materials (e.g. steam, hot
(LOPC) condensate, nitrogen, compressed CO2 or compressed air).
Tier Incident Description

3.1 Safe Operating Envelope excursion.
Process Safety Including:
Incident - Plant/equipment operated outside its design safe operating envelope.

STANDARD
3.2 Safety Critical Equipment (SCE) function compromised.
Including:
- SCE failing to operate on demand.
- Override or bypass of SCE without an approved risk assessment in
place.
- SCE found outside expected operating condition/range (e.g. found
faulty on inspection or test).
- Cyber threat to safety critical control systems and SCEs.
3.3 Non-spurious activation of an SCE.
Including:
- Operator intervention upon a safety-critical process alarm.
- Instrumented trip system activation.
- Relief valve lifting.
3.4 Unplanned or uncontrolled release of any material or energy from a process that
results in consequences less than the thresholds for an API RP 754 Tier 2
incident*.
3.5 Error or failure in complying with Process Safety Management System
Requirements
Major Accident An event connected with a Contact facility, including a natural event, involving an
Event (MAE) unintended loss of control of a hazard with the potential for critical or catastrophic
consequences (per the Contact Risk Toolkit).
The risk of MAEs is evaluated and reduced so far as is reasonably practicable
(SFAIRP).
Major Accident A Hazard which has the potential to cause Major Accident Event.
Hazard (MAH)
Process Hazard Process hazard analysis (PHA) can take many forms, including Hazard and
Analysis Operability (HAZOP) studies, bow ties, layers of protection analysis (LOPA),
quantitative risk assessment (QRA, including fault and event tree analysis).
The imperative is that all potential threats to the control of hazards are identified, that
the consequences and impacts of a loss of control are understood and that the

STANDARD
barriers that prevent the consequences from occurring are identified.
Safe Operating Safe Operating Envelopes are the outer bound of plant conditions, or the set of limits
Envelopes/Limits and conditions, within which the operation of asset, plant, process and/or equipment
must be maintained in order to comply with, e.g., regulatory requirements, safety
design criteria, performance standards and Origin safety management expectations.
Safety Critical An activity undertaken to support (or maintain) the ongoing integrity
Activity (SCA) (effectiveness/function, availability, reliability and survivability) of SCEs by ensuring
escalation factors do not inhibit SCE function and that performance standards are
being met throughout the asset lifecycle.
SCAs assure that the barrier/control remains:
 independent of the threats to loss of hazard control and other barriers/controls
implemented to manage the same threat;
 fit for purpose and continues to function per its design intent;
 reliable and available; and
 survivable such that it can perform its design function in the event of the major
accident event for which it is designed.
Safety Critical Safety Critical Documents are those that are associated with Safety Critical Elements
Documents and/or Safety Critical Activities.
Contracts used for out-sourced safety critical activities and operating/ maintenance
procedures containing safety critical work instructions are safety-critical documents.
Typically, safety critical documents are marked as such and regular revision of the
documents for accuracy and adequacy becomes in itself a safety critical task that
should be assigned to the document owner/author.
Safety Critical a) Safety Critical Elements: means any part of a Contact facility or its plant (including
Element (SCE) a computer program)—
(i) that has the purpose of preventing, or limiting the

STANDARD
effect of, a Major Accident; or
(ii) the failure of which could cause or contribute
substantially to a Major Accident.
(iii) any other part of a Contact facility or its plant that, in accordance with Contact’s
procedures, the Engineering Authority mandates is defined as a Safety Critical
Element.
Safety Critical Are a subset of Safety Critical Elements pertaining to physical equipment/systems
Equipment (hardware and software), including vessels, instrumentation, valves, pumps, control
(SCEq) systems, etc.
Safety Critical Are a subset of Safety Critical Elements pertaining to management processes,
Procedures (SCP) operating procedures, maintenance procedures, emergency response plans, etc.
Safety Critical A role that has been assigned the responsibility of completing a Safety Critical Activity
Role (SCR) (SCA). Roles may also be defined for those who are accountable (e.g. supervisors of
safety critical roles) for the assurance that the task is completed, which may in itself
be defined a SCA.
SFAIRP So Far As Is Reasonably Practicable, For the risk to be SFARP, it must be possible
to demonstrate that the cost involved in reducing the risk further would be grossly
disproportionate to the benefit gained.

STANDARD
Owner:
Author: Brendan Bleasdale
Unique Document Number:
Date of first Issue: 23/04/2015

Review due date: 01/05/2019
Current Version Synopsis of amendments to previous version

Number Date (brief commentary noting section)
1 23/04/2015 First Issue
2 2/05/2017 Routine review incorporating minor editing and format changes


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