How is safety connected to safety? What is safety and why is it important.
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Transcript of How is safety connected to safety? What is safety and why is it important.
How is safety connected to safety?What is safety and why is it important.
Heidi Fuglum
ABB - Chemical, Oil and Gas Market Development & Technology Deployment Manager
Moscow, Russia | 16-19 June, 2014
Moscow, Russia | 16-19 June, 2014
Introducing Heidi Fuglum
•Working with ABB since 1996
•Heidi has been with ABB for more than 15 years and is currently Technology Coordinator for Chemical, Oil and Gas. She lives in Oslo (Norway) but she spends most of her time in the Arab Gulf region. Her responsibilities are development of the automation market, both for new installations and installed base. Heidi is also responsible for safety systems in installed base.
•Heidi has worked on an oil platform for one year in Norway, and she has resided in Jakarta (Indonesia) and in Singapore.
•She is certified functional safety engineer from TUV
Moscow, Russia | 16-19 June, 2014
Why is safety so important?
Moscow, Russia | 16-19 June, 2014
The energy we love to hate
•Equivalent 136.000 TWh
•~ 1000 times Norwegian electricity production
•~ 6000 nuclear power plant blocks, open one each week for 115 years.
Source: International Energy Agency (IEA)
Moscow, Russia | 16-19 June, 2014
Carbon emissions from different sources
Coal continues to account for the largest share of energy-relatedcarbon dioxide emissions throughout the projection
Source: Energy Information Administration (EIA)
World energy-related carbon dioxideemissions by fuel type – 1990-2040 (billion metric ton)
Moscow, Russia | 16-19 June, 2014
The energy we love to hate
•Largest windfarm planned is 200 mills at 2 MW with annual production 1,2 TWh
•To replace oil and gas consumption, 113.000 such farms, with a total of 23 million mills is needed.
•At 100 meters distance, this will go 60 times around equator
Source: International Energy Agency (IEA)
Moscow, Russia | 16-19 June, 2014
Longer, deeper, colder… and olderEnsuring safe, efficient and sustainable operations
Moscow, Russia | 16-19 June, 2014
Key concepts to managing safetyProcess (Technical) Safety
Functional Safety
Personal or Occupational Safety Managing Major Accident Hazards, with particular focus on managing the
containment of hydrocarbons and chemicals
Slips, trips & fallsPersonel Protection EquipmentLockout-tagoutConfined space workingHot working Instrumented
Functional Safety
Product Safety
Overall Safety Management & Culture
Interlocks, Alarms & Trips
Safe for Intended Use
Human FactorsAlarm managementHuman failure modesDesigning out problemsBehavioral safetyCompetency management
Moscow, Russia | 16-19 June, 2014
Safety fundamentalsHazard and Risk
Hazard has the potential to cause harm through
• Injury
• Illness
• DamageRisk is a combination of
• The probability of occurrence of harm
• The severity of the harm
•Want to reduce risk to protect:
• People
• Environment
• Business
Moscow, Russia | 16-19 June, 2014
Risk matrix
ConsequenceCategory Risk MatrixCategory 5
Extremely Serious
TOLERABILITY BAND
No action necessary
- If ALARP
Category 4
Major Consequence
TOLERABILITY BAND
No action necessary
- If ALARP
Category 3
Sev ere
Consequence
TOLERABILITY BAND
No action necessary
- If ALARP
Category 2
Serious
Consequence
TOLERABILITY BAND
No action necessary
- If ALARP
Category 1
Signif icant
Consequence
TOLERABILITY BAND
No action necessary
- If ALARP
1 2 3 4 5
10-7 10-6 10-5 10-4 10-3 10-2 10-1 1 10
Extremely Very Unlikely Possible Probable
Unlikely Unlikely Unlikely
1 2 3 4 5
High Risk
Low Risk
Likelihood
Moscow, Russia | 16-19 June, 2014
Risk matrixConsequence
Category
Category 5Extremely Serious
TOLERABILITY BAND
No action necessary- If ALARP
Category 4Major Consequence
TOLERABILITY BAND
No action necessary- If ALARP
Category 3Sev ere
Consequence
TOLERABILITY BAND
No action necessary- If ALARP
Category 2Serious
Consequence
TOLERABILITY BAND
No action necessary- If ALARP
Category 1Signif icant
Consequence
TOLERABILITY BAND
No action necessary- If ALARP
1 2 3 4 5
10-7 10-6 10-5 10-4 10-3 10-2 10-1 1 10
Extremely Very Unlikely Possible ProbableUnlikely Unlikely Unlikely
1 2 3 4 5
Likelihood
Process Safety
High
LowPersonalSafety
Major Incident Triangle
Personal Incident Triangle
Consequence Major incident
ConsequenceHigh Potential Incident
IndicatorDetail breachesConsequence
Unsafe actsvIndicator
Near misses
ConsequenceMinor injury
Consequence Major incident
Personal vs Major incidents, indicators
Source: Woodgroup
Moscow, Russia | 16-19 June, 2014
Protection is multiple protection layers
Risk Reduction using LOPA
Emergency response layer
Passive protection layer
Active protection layer
Safety layerEmergency shutdown
Process shutdown
Processvalue
Trip level alarm
Process control layer
Process alarm
Process control layerNormal behaviour
Plant and EmergencyResponse
Dike
Relief valve,Rupture disk
SafetyInstrumentedSystem
OperatorIntervention
Basic ProcessControlSystem
Moscow, Russia | 16-19 June, 2014
Key concepts to managing safetyProcess (Technical) Safety
Functional Safety
Personal or Occupational Safety Managing Major Accident Hazards, with particular focus on managing the
containment of hydrocarbons and chemicals
Slips, trips & fallsPersonel Protection EquipmentLockout-tagoutConfined space workingHot working Instrumented
Functional Safety
Product Safety
Overall Safety Management & Culture
Interlocks, Alarms & Trips
Safe for Intended Use
Human FactorsAlarm managementHuman failure modesDesigning out problemsBehavioral safetyCompetency management
Moscow, Russia | 16-19 June, 2014
Different types of safetyHealth, Safety and Environment
Moscow, Russia | 16-19 June, 2014
The Subsea Factory – environmental challenges
Moscow, Russia | 16-19 June, 2014
Different types of safetyProcess Safety
Moscow, Russia | 16-19 June, 2014
Different types of safetyFunctional Safety (“Automation Safety”)
Controller
Level Switch
Solenoid
Pump
SIF A
SIF B
SIF C
SIF D
Safety Instrumented System with multiple SIF’s
Moscow, Russia | 16-19 June, 2014
Different types of safetyFunctional Safety
IEC 61511
•Defines 61508 application in Process Sector
•Defines the Application of Safety Instrumented Systems for the Process Industry
Moscow, Russia | 16-19 June, 2014
Different types of safetyProduct Safety
Moscow, Russia | 16-19 June, 2014
Why focus on operators?Operator effectiveness generates substantial savings
Global process industry looses $20 billion (5% percent of annual production) due to unscheduled downtime and poor quality
80% of these losses are preventable, 42% result primarily from operator error
Huge increase in amount of information dramatically increases risk for stress in critical situations
Distribution of unscheduled shutdowns and slowdowns in %
Moscow, Russia | 16-19 June, 2014
The evolution of operator controlSignificant increase in complexity and span of control
Moscow, Russia | 16-19 June, 2014
Different types of safetyHuman Factors
• Who’s hurt, who just needs a cuddle, who should I pick up first?
• What should I do?
• When Mathias starts crying, why does Peter always start crying as well?
Moscow, Russia | 16-19 June, 2014
Different types of safetyHuman Factors
• Hundreds of screaming babies….and we expect the operator to register and respond to all babies that are hurt?
• Alarm Management essentials - make sure the operator picks up the right baby every time.
Moscow, Russia | 16-19 June, 2014
Different types of safetySafety Culture
SafetyCommunication
SAFETY
CULTURE
Management commitment
Supervisory commitment
Teamwork
Safety rules& procedures
Workforce involvement
Training
OrganizationalLearning
ReportingSystem
Workpressure
Moscow, Russia | 16-19 June, 2014
Source: Energy Information Administration (EIA)
Moscow, Russia | 16-19 June, 2014
How can we get the energy supply we need in a safe and sustainable way?
Oil and Gas•Electrification•Subsea
Power Grid Smart Community•Shore to Ship
Industry automation•Data Centers