OPERATIONS PROCESS SAFETY FUNDAMENTALS

Presented by:
Badar Al Ghaithi, PDRN2
15th July 2020
 Non Negotiables PSF

Operations Engineering Wells

PSFs Forward Path ONO OSO GGO OSGO Infra 1. People are Certified (IWCF, Licensing, OSC)
PSF# 1 Always ensure two barriers are in place for Conduct survey and develop scope
hydrocarbon and chemical drains & vents All assets to perform survey Provide double A3 A3 A3
barriers
PSF# 2 Do not leave an open drain or critical transfer Implement Jan 2019 2. Two Barriers maintained at all time (Primary & Secondary)
unattended Issue Standing Instruction

PSF# 3 Define interim mitigation measures for any defective Gap closure during 2019. Implement in 2020.
Safety Critical Element and ensure controls are effectively Continue improvements as per A3s A3 A3 A3 A3 A3 3. Barriers are tested & reported (P/T, IFT)
implemented
PSF# 4 For all defined high risk activities, follow the Define scope
procedures and sign off after each step Develop checklists for high risk activities A3 A3 A3 A3 A3
PSF# 5 Walk the Line – Verify and validate any line up change Implement Jan 2019 4. Equipment is Certified (COC/COS)
Issue Standing Instruction

PSF# 6 Do not make a change without a MOC Gap closure during 2019. Implement in 2020.
Continue improvements as per A3s A3 A3 A3
5. Well Control Drills are performed & recorded
PSF# 7 Verify for complete tightness after maintenance work Gap closure during 2019. Implement in 2020.
Continue improvements as per A3s A3 A3 A3
PSF# 8 Always check that equipment & pipes are Gap closure during 2019. Implement in 2020.
depressurized, drained and safely isolated before opening Continue improvements as per A3s
A3 6. Well Control Critical Equipment in place (i.e. PVT, TT, EKDS)

PSF# 9 When connecting utilities to process ensure backflow Implement Jan 2019
protection is installed Continue improvements as per A3s A3 7. Critical Procedures are complied with;
PSF# 10 Respond to critical alarms Gap closure during 2019. Implement in 2020. • Trip / Strip Sheet / Kill Sheet, Alarms calibrated & set
Continue improvements as per A3s A3 A3 A3 A3 • Approved Programs / SWI / MOC
 What does Process Safety mean to you?

Process Safety in Operations is about…

1) Keeping the hydrocarbons in the pipe
2) Staying within the operating window
3) Correctly preparing equipment for
maintenance and restart
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 Why is Process Safety important?
Process Safety Events continue to occur frequently in our business, with impact on our people, communities, assets &
environment.

Catastrophic
Preventing Process Safety
Event incidents is important because
they can escalate into
Tier 1 catastrophic events.
PS Incident
Tier 2
Process Safety (PS) Incident

Other LOPC

Demand on Safety Systems Process Safety Fundamentals

emphasize existing good
Safe Limits Exceedance practices to reduce unsafe acts
and conditions.
Unsafe Act & Conditions

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 Process Safety in Our Workplace
Process Safety Fundamentals
will guide daily actions you can take
to prevent these incidents from
happening again

Bahja 2016
Process Safety Fundamentals are different from life saving
rules:
Life Saving Rules are policies focused on the prevention of
personal safety incidents, while Process Safety Fundamentals
are intended to prevent process safety incidents.
They are not asking you to do anything new, only to focus more
closely on critical tasks that already included in your current
work requirements.

5
Yibal 2012
 Operations Process Safety Fundamentals
PSF #3 Define interim
PSF#1 Always use two PSF#2 Do not leave an mitigation measures for any PSF#4 For all defined high PSF#5 Walk the Line –
barriers for hydrocarbon open drain or critical defective SCE and ensure risk activities, follow the Verify and validate any line
and chemical drains & transfer unattended controls are effectively procedures and sign off up change
vents implemented after each step

PSF#6 Do not make a PSF#7 Verify for complete PSF#8 Always check that PSF#9 When connecting PSF#10 Respond to critical
change without an MOC tightness after any work equipment/piping is utilities to process alarms
depressurized, drained and perform an MOC and
safely isolated before opening install backflow protection
 PSF #1 Always use two barriers for hydrocarbon and chemical drains & vents
Why is this important?
Relying on a single barrier, such as a drains and vents with an open ended valve, has led to significant releases and Process Safety Incidents.
Having a second barrier in case of failure (of the first barrier) is shown to significantly reduce the risk and keep us safe during these critical
activities.
Scope:This PSF scope only includes vents and drains that can result in a release to the environment. Vents and drains to closed systems,like
flare or closed drains are outside the scope of PSF.
As a LEADER you should: As the FRONT LINE you should:
•Help to proactively identify systems that don’t currently •Close vent and drain valves, and install
have two barriers and provide a safe solution. caps, plugs or blind flanges after each use.
•Confirm the use of two barriers (connected to an open •Close both (two) valves at sample points
system) during daily field rounds. after taking samples.
•Confirm that two barriers are considered when reviewing •Make sure that spectacle blinds; end
work permits. flanges; caps; plugs are restored after
•If two barriers can’t be reasonably installed, define maintenance work
measures to make the task safer in the interim

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 PSF #2 Do not leave an open drain or critical transfer unattended

Why is this important?

Leaving a drain or vent valve open and unattended has resulted in hazardous material releases,overfilling during bulk transfers and process
safety incidents.
Scope:This PSF includes vents and drains to atmosphere and also filling and tank transfer operations

As a LEADER you should: As the FRONT LINE you should:

•Ensure that all critical transfers at your site are identified and
•Drain or remove volatile hydrocarbon liquids from
understood. equipment in closed systems.
•Support scheduling and work planning to ensure that
•Do a risk assessment where open draining of volatile
operators have the proper time to attend to critical transfers. material can’t be avoided and obtain proper approval for
•Make sure that all potential release points are identified in open draining.
the procedure and in the field. •Always be present when draining fluids from equipment
•If the procedure does not cover the draining/venting or tanks containing hydrocarbons or hazardous materials,
activity then make sure that the associated risks and (or the potential to contain hydrocarbons or hazardous
consequences are known to the relevant personnel. materials) and immediately close the drain valve when
•Ensure that your team understands the risk of blockages and draining of fluids is completed.
obstructions during draining activities •Never leave bleeders on block and bleed isolations in
hydrocarbon and hazardous material service unattended
when open to the atmosphere

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PSF #3 Define interim mitigation measures for any defective SCE and ensure controls are effectively implemented

Why is this important?

Safety Critical Equipment is an essential barrier protecting us from significant Process Safety Incidents. Safety Critical Equipment must
work correctly to keep us safe in the event that process conditions escalate beyond the operating window

As a LEADER you should: As the FRONT LINE you should:

•Know the role of each piece of Safety Critical Equipment and •Know the role of Safety Critical Equipment in your area.
verify that all are identified in the asset management system. •Intervene if barriers are missing or found not healthy.
•Ensure adequate safety barriers are in place for every •If you are not sure about healthiness of the
operation, and that the relevant personnel not only know about barriers then - STOP and confirm before you proceed.
it but also understand how to respond when they fail. •Report all lost/failed barriers to your supervisor.
•In case of a lost barrier: Refer to the MOPO and determine if
•Follow procedures on how to manage failure of IPFs,
you can continue to operate.
relief valves, and pressure relief systems.
•Know the Performance Standards and understand when a
•Follow a written mitigation plan if the SCE cannot be
barrier has actually failed. Consult the assigned TA for further
repaired within the required time frame.
guidance.
•Assure interim measures are in place and effective.
•Make sure that effective,independent and auditable mitigation
measures are in place, and verify that temporary mitigation
measures continue to be robust until repairs are complete.
•Assure that hardware barriers are tested and remain valid.
•When working on Safety Critical Equipment, confirm work is
executed by a person with the appropriate competency. 11
 PSF #4 Follow the procedures and sign off after each step for all high risk activities

Why is this important?

Procedures are an important barrier as they help ensure that all work is performed in a correct, safe, and consistent manner. The likelihood
of a Process Safety Incident is higher during startups, shutdowns and upsets rather than during normal operation.

As a LEADER you should: As the FRONT LINE you should:

•Ensure that all high risk activities at your site are •Know which procedures have been identified for high risk

identified and understood. activities. Understand and always follow these procedures.
•Sign off real time as the procedure is executed (except for
•Know the standards and procedures, and ensure they
emergency shutdown procedures).
are available and accessible. •Sign off within 24 hours after the procedure is executed for
•During high risk activities, monitor that the correct emergency shutdown procedures.
procedure is being used and signed off. •Do not deviate from procedures - Escalate to shift management if
•Ensure that procedures have the appropriate hold procedure steps cannot be carried out as written.
points and escalation steps for when issues arise. •Stop the job if conditions are not going in accordance with the
•Take ownership of standards and procedures – make plan.
•Provide feedback if procedures are unclear or can be improved
sure they are regularly reviewed, updated.

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 PSF #5 Walk the line – Verify and validate any line-up change

Why is this important?

Correct Operational line-ups verification and validation ensures that process and utilities streams are routed to the right locations.
Incorrect line-ups can misdirect the process into equipment not designed for it and can therefore lead to process safety events
(excessive temperatures, pressures, or levels, leading to spills, overfills,explosions etc).

As the FRONT LINE you should:

As a LEADER you should: Confirm, by visual examination, that the PEFS reflect the
•Ensure thorough line-up walks are carried out and
current conditions (as built) before starting work and also the
master PEFS mark up is correct.
checklists are signed. Assure line-up verifications via ‘Go
& See’ walks. Verify upstream and downstream valves are in the correct
•Review completeness of pre-startup checks before
positions for all line-up changes by physically walking the
lines before and after work.
taking equipment into operation.
•Ensure temporary hook-ups are installed exactly as
Validate that line-up changes are as intended eg. by checking
the process parameters (levels, temperature etc).
designated in the MOC.
•Mark up on the master PEFS any line up change
If any of these conditions don’t look or feel right, STOP the
work and consult your supervisor.
identified.

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 PSF #6 Do not make a change without MOC

Why is this important?

Unauthorised changes can lead to significant incidents, including releases, fires, explosions and fatalities. Management of Change is essential to
ensure that the correct people are involved and provide inputs into any irregular change to process facilities.

As a LEADER you should: As the FRONT LINE you should:

•Proactively identify where Management of Change is required.
•Know how to recognize a change, and be vigilant to
•Assure the correct Management of Change process is followed.
•Document the change using a proper MOC and identify the changing conditions in the field.
correct parties to consult. •Ensure any temporary connection or set-up is approved
•Review and approve the design or plan including hazard screening
and risk analysis. and documented via an MOC.
•Communicate changes to your team. •Do not accept a change where the installation doesn’t
•Execute the change and train the people affected by the change. accurately look like the design documentation and/or
•Only implement a change after it has received all required
where the critical documentation is not fully updated or
approvals via the MOC process.
•Ensure that issues identified by the Front Line during completed
implementation and commissioning are acted on by the MOC
owner or coordinator.
•When the change work is completed, ensure that any necessary
Pre-Startup Safety Reviews have been carried out prior to any
commissioning activity.
•Verify that all affected documentation is properly updated

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 PSF #7 Verify for completeness of tightness after maintenance work

Why is this important?

Verifying that equipment and piping are sufficiently tight can prevent releases when hydrocarbons or hazardous chemicals are introduced into
the system after maintenance. In order to reduce this risk it is best to check for leaks under controlled conditions.

As a LEADER you should: As the FRONT LINE you should:

•Ensure that tightness has been checked under controlled •Understand and follow flange management procedure.
conditions (e.g. leak test using air/nitrogen) following •Before introducing hydrocarbon or hazardous chemicals into
maintenance activities that involved breaking containment of the system Verify that the system is mechanically complete.
the system. •Close all drains or bleeders.
•Confirm that work plans include thorough commissioning •Remove any temporary connections.
instructions. •Reinstate instrumentation.
•Review the completion and sign off of checklists before
•Perform a system leak test and investigate any leaks.
introducing process fluids to the system.
•Confirm the line-up, and that all drains and bleeders are in
•When specific leak testing procedures exist for maintenance of
place.
identified equipment, be sure that they are made available and
•Do not leave piping or equipment unattended during re-
followed.
introduction of hydrocarbons or chemicals, for timely detection
of any unusual conditions.

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 PSF #8 Always check that equipment/piping is depressurized, drained and safely isolated before opening

Why is this important?

Effective process isolation and verification that equipment/piping is pressure free ensures that personnel will not get hurt due to a
release of pressure while equipment is open for maintenance.

As a LEADER you should: As the FRONT LINE you should:

•Know the isolation procedure, and verify that Front Line •Ensure that an approved isolation plan is available for
staff have been trained and understand it. every maintenance activity that requires breaking into a
•Ensure that isolation plans are properly approved and pressure envelope.
managed to provide a safe place of work. •Confirm the right level of isolation is in place before
•Always use accurate PEFS to create isolation plans. allowing maintenance work to start.
•Verify that planned isolations can realistically be executed •Confirm that there is no pressure in the system before
and the field installation accurately reflects the plan. allowing maintenance work to start. Pressure-free
•Understand and confirm feedback on defective isolation condition is to be determined using
equipment (like passing valves), and work to have these available instrumentation or vents/drains .The use of a
repaired in due time. ‘first flange break’ can only be used as a last resort.
•Assume the hazard will be present during first break and
•Ensure that valves critical to isolations are properly
maintained. therefore use the right PPE before allowing work to start.
•Do not change isolations plans without supervisor
•Verify that non-routine isolation plans are developed.
approval.
•Prescribe and confirm the right PPE.
•Provide feedback to supervision on isolation equipment
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that doesn’t work properly.
PSF #9 When connecting utilities to process perform an MOC and install backflow
protection

Why is this important?

Reverse flow of hydrocarbons and chemicals into utility systems has resulted in several significant incidents.
Scope: All temporary utility connections and/or chemical injection to the process.

As a LEADER you should: As the FRONT LINE you should:

•Understand all of the hazards of cross •Do not connect utilities to process unless absolutely
contamination into utility/injection chemical necessary.
systems and communicate this with the Front •Use MOC for temporary connections to the process.
Line. •Always install backflow prevention (such as a check
•Ensure that all alternative options have been valve) when connecting utilities to process or other
considered before connecting utilities to utility systems.
process.
•Confirm that an MOC is in place and backflow
scenario/risk has been taken into account
where cross connections are observed during
field visits.

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 PSF #10 Respond to critical alarms

Why is this important?

Process alarms are part of the response against process upsets and allow the operator to take action before the safety system such as trips
are activated. Both the recognition of the critical alarm and the board /field operator responses are needed for the barrier to be robust and
complete. The Variable Table is an essential resource to ensure the correct and prompt response to each critical alarm in the event of a
process upset.

As a LEADER you should: As the FRONT LINE you should:

•Understand which alarms are critical and know your role •Understand which alarms are critical and ensure that all critical
in responding as a supervisor. alarms are acknowledged and acted upon.
•Assure the accuracy and usability of the variable table. •Use the variable table to retrieve the required response.
•Respond promptly to operator concerns where the •Highlight inadequate or incorrect variable table responses to
variable table is inaccurate. supervision.
•Drive the alarm rate at your facility to a level that gives •For critical alarms, practice - Stabilize, Slowdown, Shutdown
the operator time to respond (below 6 alarms per hour). •Raise concerns with supervisor when some unusual
•Use the process for managing bad actors, alarm floods, alarm arises.
nuisance alarms, etc •Do not inhibit/mute critical alarms unless the consequences of
doing this have been assessed. Inhibiting a critical alarm
requires an MoC and registration in the override register.
•Notify your supervisor of periods where alarm management in
difficult
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 Process Safety Fundamentals will move us closer to
Goal Zero, so you should…
 Get familiar with the reference guidance and ask questions if
anything is unclear.
 Make it part of your every day.
 Share your ideas.
 These ten operations fundamentals are a way of caring for
each other and are crucial in keeping everyone safe on site.
 Your actions count!
 Process Safety Consequence Management
Operations
OPSF#3 Define interim OPSF#8 Always
OPSF#1 Always OPSF#2 Do not OPSF#4 For all OPSF#5 Walk the Line OPSF#6 Do not OPSF#7 Verify for
mitigation measures check that OPSF#9 When OPSF#10 Respond
ensure two barriers leave an open defined high risk – Verify and validate make a change complete tightness
for any defective equipment and connecting utilities to critical alarms
are in place for drain or critical activities, follow any line up change without an MOC after maintenance
Safety Critical to process ensure
hydrocarbon and transfer the procedures pipes are
Element & ensure work backflow protection
chemical drains & unattended and sign off after depressurized,
controls are effectively drained and safely is installed
vents each step
implemented isolated before
opening

Wells

WPSF#1 Trained WPSF#2 Lost WPSF#3 Barriers WPSF#4 Well WPSF#5 Emergency WPSF#6 Walk The WPSF#7 Standards & WPSF#8 Subsurface WPSF#9 Risk Assess WPSF#10 Report /
People Barrier Know your physical Control Equipment Response Line Procedures Uncertainties Perform risk Learn
Confirm all People are If a barrier is lost well barriers and Know your well Test your emergency "walk the line" on Follow standards and Know and assessment during Report Wells Process
trained and competent ,immediately stop confirm they are control equipment responses and temporary rig-up & procedures or get communicate planning and for Safety incidents -
for the task. and fix it. tested. and confirm it's conduct regular drills confirm the set-up -- approval to deviate subsurface changes investigate, share,
certified and tested layout drawing. uncertainties learn
.

Engineering
EPSF#1 Comply EPSF#3 Complete all EPSF#4 Comply to EPSF#5 Do not deviate EPSF#6 Obtain relevant TA EPSF#7 Walk the line and
EPSF#2 Obtain relevant
with applicable SCE equipment PMOC process for from MSR without approval for engineering verify line up against PCC
TA approval before
DEM1 & DEM2 identification, managing changes relevant TA approval for reviews actions close out
deviating from “Shall”
requirements registration and linking all project phases and do not close on intent
statements
to performance
standards

First non-compliance to any item from the

above Process Safety Fundamentals First Warning Letter and Coaching

Second non-compliance to any item from

the above Process Safety Fundamentals Final Warning Letter and Coaching

Third non-compliance to any item from the

above Process Safety Fundamentals Dismissal

Note: Depending on the investigation outcome and the damage occurred to (Life, Assets, Environment & Reputation), a more serious consequence management may be taken
 PROCESS SAFETY FUNDAMENTALS GUIDE

New Guide GU-947 available in CMS covering

• Why each PSF is important
• Scope and Exceptions
• Application Guidelines
• Roles and Responsibilities
• FAQ’s
• Step out mechanism
• For simplifying the message the PSF animations are available
on PDO tube